Method and apparatus for the filtration of biological samples

ABSTRACT

A separation module and method are disclosed for processing a liquid sample and providing high conversion by operating a single-pass tangential-flow process without a recirculation loop. In one embodiment, the separation module includes three reservoirs and has at least one long, thin channel with a large ratio of channel membrane area to: channel void volume; volume of a sample feed reservoir; and volume of the feed sample. In another embodiment, the separation module includes an external feed reservoir, an external retentate reservoir fluidly and a first vacuum source adapted to apply a first vacuum to the separation element disposed within the housing. The single-pass TFF separation element and single-pass process provides high conversion while operating with relatively low pressure sources. Certain embodiments disclosed herein can be used for the separation of blood.

RELATED APPLICATIONS

This application is a Continuation in part of patent application Ser.No. 12/371,611 filed Feb. 15, 2009, now U.S. Pat. No. 8,231,788, grantedJul. 31, 2012, and claims benefit of 61/234,286, filed Aug. 15, 2009,and is a continuation of application Ser. No. 11/615,031 filed Dec. 22,2006 now U.S. Pat. No. 7,510,654, granted Mar. 31, 2009 and which claimsthe benefit of U.S. Provisional Application No. 60/755,009, filed Dec.29, 2005, and U.S. Provisional Application No. 60/754,813, filed Dec.29, 2005, which applications are hereby incorporated herein by referencein their entirety.

STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH

This invention was made with government support under Grant NumberGM-079876 awarded by the National Institutes of Health. The governmenthas certain rights in the invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to a sample preparation modules andmethods and more specifically to single-pass tangential flow filtrationmodules for the concentration of liquid samples.

2. Description of the Related Art

Ultrafiltration (UF) and microfiltration (MF) membranes have becomeessential to the separation and purification in the manufacture andresearch of biomolecules. Biomolecular manufacturing and laboratorysample preparation, regardless of the scale, generally employ one ormore processing steps including filtration (UF or MF). Theattractiveness of these membrane separations rests on several features:including, for example, high separation power, and simplicity (e.g.,requiring only the application of a pressure differential between thefeed sample and the final product permeate). This simple and reliableone step separation of the sample into two fractions makes membraneseparation processes a valuable approach to separation and purificationof the final product.

In one class of membrane separations, the species of interest is thatwhich is retained by the membrane, and the objective of the separationis typically to remove smaller contaminants, to concentrate the desiredproduct in the retained solution, or to affect a buffer exchange. Inanother class of membrane separations, the species of interest is thatwhich permeates, and the objective is typically to remove the largercontaminants from the starting sample. In MF, the retained species aretypically particulates, organelles, bacteria or other microorganisms,while those that permeate are proteins, colloids, peptides, smallmolecules and ions. In UF the retained species are typically proteinsand, in general, macromolecules, while those that permeate are peptides,ions and, in general, small molecules.

The ability to maintain a reasonably high flux is essential in thepractice of membrane processes. Low flux can result in long filtrationtimes or large modules, resulting in increased cost and large hold-upvolumes (i.e., the volume including the retained species remaining inthe module). The filtration process itself induces the creation of ahighly concentrated layer of the retained species on the surface of themembrane, a phenomenon called “concentration polarization” (or simply“polarization”), which reduces the flux from an initial value obtainedimmediately at the start of filtration. In the absence of countermeasures the accumulation of “polarized” particles or solutes results invanishingly small fluxes and bringing the processes to a stand-still.One conventional approach to overcoming the effects of concentrationpolarization is to run the separation in “tangential flow filtration”(TFF) mode.

TFF modules are devices having flow channels formed by the membranethrough which the feed stream flows tangentially to the surface of themembrane. The tangential flow induces a sweeping action that removes theretained species and prevents excessive accumulation, therebymaintaining a high and stable flux. Because higher tangential velocitiesproduce higher fluxes, the conventional practice of TFF calls for theuse of high velocities in the flow channels, which in turn result invery high feed rates. These high feed rates result in low conversion,typically less than 10% and often less than 5%. Low conversion meansthat the bulk of the feed stream exits the module without having beensubstantially separated from the permeate.

One commercially important area for UF separations and purification isat the preparation of analytical samples (e.g., sample volumes less than500 ml). The application of conventional TFF processes to samplepreparation at the analytical scale is generally believed not to bepractical due to the complications in the use of pumps and recirculationloops which are normally required for TFF processes. As a result, UFseparations at these scales are practiced almost exclusively in a“dead-ended” mode, resulting in an inherently low flux due toconcentration polarization. Centrifugal UF devices have been developedfor this scale to mitigate the low flux of dead-ended UF separations.However, while these have become the dominant format for analyticalscale UF, they typically require centrifuges capable of exposing the UFdevice to accelerations as high as 14,000 g. Furthermore, in spite ofthese accelerations, many separations still require long times, oftenone hour or more. Finally, the recovery of the retentate presentsspecial difficulties in these approaches since it may be spread as athin film over the surface of the membrane.

One prior art device disclosed in U.S. Pat. No. 4,761,230, Pacheco, etal., includes first and second housing sections with a flow channelextending therebetween. A membrane filter forms one boundary of the flowchannel. A pair of reservoirs, one for feed and the other for permeatecollection, are integrally formed with the first housing section. Afluid communication path is established from the first section to thesecond section and then through means of a deformable chamber to theflow channel. The deformable chamber is adjacent to a rigid surface thatis integral with one of the housing sections and in this manner isadapted to pump fluid through the system when interfacing with a pump.This device also operates in a continuous recirculation mode duringconcentration of batch samples and includes a recirculation loop.

U.S. Pat. Nos. 6,692,702, Burshteyn, et al. and 6,692,968, Burshteyn, etal, teach a method for utilizing a filtration device for removinginterferants from a sample containing cells in an automated apparatus isdisclosed. The filtration device includes a microporous hollow fibermembrane having a plurality of pores sized to retain cells whileallowing smaller diameter interferants to pass through the membrane. Theapparatus also includes a means for moving the sample from a samplecontainer to and from the filtration device. The disclosed methodutilizes a vacuum source to aspirate the sample into a lumen of thehollow fiber membrane so that the sample is retained in the lumen spaceuntil expelled into an analysis container or transported to an analyzer.

Filtration technology (microfiltration (MF) and ultrafiltration (UF)) isone of the most powerful bioseparation technologies available and,although well-known and practiced in many laboratories, it remains afringe technology in the preparation of whole blood, plasma or serumsamples. The main reasons are that existing MF/UF devices require acentrifuge, take a considerable amount of time to process samples, andin the case of whole blood, they do not work at all. Furthermore,centrifugation is costly and makes it difficult to process multiplesamples at the same time.

None of the prior art devices and methods provide rapid, controlledconversion without the use of numerous venting valves, recirculationloops and pumps in addition to simple construction and operation. Thus,the need exists for devices and processes suited for sample preparationin life science and diagnostics laboratories which are able to yieldhigh reliable flux and high conversion without the need of recirculationloops, numerous valves and intermediate pumps, and that can be readilydriven by the low-pressure differentials and which are simple tocontrol. It would also be desirable to operate a bio-processingseparation at the sample preparation scale in a single-pass mode whileproviding a high conversion with a relatively low hold up volume andeffective recovery of the separation products.

Furthermore, while ultrafiltration membranes are capable of separatingsmall molecule drugs and hormones from large and abundant species (e.g.albumin, among others), conventional centrifugal UF devices are notcapable of processing whole blood. Although the existing (UF)centrifugal devices are capable of fractionating plasma or serum, ittakes a very long time to fractionate solutions with proteinconcentrations greater than about 0.5%, far exceeding the fastturn-around demands of a clinical laboratory. For that reason,centrifugal UF devices have found little use in clinical laboratoriesfor free drug/hormone assays.

In particular there is a need for a blood sample collection device thatfractionates blood at the time of collection and makes it immediatelyready for subsequent tests. Such a device would make it possible tosignificantly reduce the time required for typical clinical assays.Also, with the use of UF membranes such a device would allow thecollection of a fraction containing only free drugs/hormones, therebyenabling direct determination which is difficult or not even possible ina many clinical settings.

SUMMARY

It has been discovered that the use of separation modules suitable forsample-preparation having long thin channels with relatively largeratios of channel membrane area to channel void volume, to volume of asample feed reservoir, and to volume of the feed sample, can yieldrelatively fast, high-conversion, low hold-up-volume, single-pass TFF(SPF) separations that can be driven with low pressures.

In accordance with one aspect of the present invention, a separationmodule for the filtration of a liquid sample includes a separationelement having at least one flow channel with an inlet, an outlet and asurface including an ultrafiltration membrane. The module furtherincludes a feed reservoir fluidly coupled to the channel inlet, aretentate reservoir fluidly coupled to the channel outlet, a permeatereservoir fluidly coupled to the separation element. The ratio of themembrane area of the separation element to the volume of the feedreservoir is greater than about 2 cm⁻¹. Such a module is capable ofprocessing a sample in a single-pass mode while providing a highconversion with a relatively low hold up volume. The module yields highreliable flux and high conversion without the need of recirculationloops, numerous valves and intermediate pumps.

In accordance with a further aspect of the invention a separation modulefor the filtration of a liquid sample includes a separation elementhaving at least one flow channel with an inlet, a surface comprising afiltration membrane; and a hydrophobic vent affixed to the channeldistally from the inlet. The module further includes a feed reservoirfluidly coupled to the channel inlet; and a permeate reservoir fluidlycoupled to the separation element. Such a module is capable ofprocessing a sample in a single-pass mode without valves for venting andneeds only a single low pressure source.

In accordance with still another aspect of the invention, a separationmodule for the filtration of a liquid sample includes a separationelement having flow channel with an outlet and a surface comprising afiltration membrane. The module further includes a feed reservoir, apermeate reservoir fluidly coupled to the outlet and the flow channel isdisposed within the feed reservoir. Such a module is capable ofprocessing a sample in a single-pass mode using outside-in flow. In oneembodiment, the specific membrane area of the module described below isgreater than about 2 cm⁻¹.

In accordance with still another aspect of the invention, a separationmodule for the filtration of a liquid sample includes a hollow fiberhaving a thick wall forming a permeate reservoir and a thin lumenadapted to provide capillary motion of the liquid within the lumen. Sucha module is capable of processing a very small sample in a single-passmode using capillary forces as the permeation driving sources.

In accordance with another aspect of the invention a method forfiltering a liquid sample includes the steps of supplying apredetermined volume of the liquid sample into a feed reservoir of aseparation module, inducing the tangential flow of the liquid sample inthe at least one flow channel by applying a first pressure differentialbetween the feed reservoir and retentate reservoir, and inducing thepermeation of a portion of the liquid sample through the filtrationmembrane into the permeate reservoir by applying a second pressuredifferential between one of the retentate reservoir and permeatereservoir and the feed reservoir and permeate reservoir. The separationmodule includes a separation element having at least one flow channelhaving an inlet, an outlet and surface comprising a filtration membrane.The separation module further includes the feed reservoir fluidlycoupled to the channel inlet, a retentate reservoir fluidly coupled tothe channel outlet, and a permeate reservoir fluidly coupled to theseparation element, and has a ratio of the membrane surface area of theseparation element to the volume of the feed reservoir which is greaterthan about 2 cm⁻¹. With such a technique, single-pass sample processingcan be readily driven by low pressure differentials which are simple tocontrol. In addition, independent control of trans-channel pressure(TCP) and trans-membrane pressure (TMP) is possible and providesefficient use of the relatively large membrane area in the separationelement to yield high controllable conversion by controlling residencetime in the flow channel regardless of the length of the channel. Such atechnique is useful in recovering the retentate fraction of a processedsample using a 3-volume device, having feed, retentate and permeatereservoirs.

In accordance with another aspect of the invention a method forfiltering a liquid sample includes the steps of supplying apredetermined volume of the liquid sample into a feed reservoir of aseparation module, inducing the permeation of a portion of the liquidsample through the filtration membrane into the permeate reservoir byapplying a pressure differential between the feed reservoir and permeatereservoir, and inducing the flow of the liquid sample in the at leastone flow channel by venting the flow channel. The separation moduleincludes a separation element having at least one flow channel having aninlet and a surface comprising a filtration membrane. The separationmodule further includes the feed reservoir fluidly coupled to thechannel inlet, and a permeate reservoir fluidly coupled to theseparation element, a hydrophobic vent affixed to the channel distallyfrom the inlet, and has a ratio of the membrane surface area of theseparation element to the volume of the feed reservoir which is greaterthan about 2 cm⁻¹. With such a technique, single-pass sample processingcan be readily driven by one low pressure differential without having tocontrol valves to vent the flow channel. Such a technique is useful inrecovering the permeate fraction of a processed sample using a 2-volumedevice, having feed and permeate reservoirs.

In accordance with another aspect of the invention a method forfiltering a liquid sample in a sample reservoir includes the step ofdipping a hollow fiber separation module into the sample reservoir. Themodule includes a separation element having a lumen with anultrafiltration membrane and having an inlet, a flow channel coupled tothe inlet, and a wall at least partially surrounding the channel. Themethod further includes the steps of drawing a predetermined volume ofliquid sample into the lumen by capillary action by leaving the moduleinlet in the sample reservoir for a predetermined time, inducing thetangential flow of the liquid sample in the lumen by capillary action,and inducing, by capillary action, permeation of a portion of the liquidsample through the lumen membrane into a permeate reservoir formed by aninner and outer surface of the lumen wall.

Disclosed embodiments employing long thin flow channels and relativelyhigh ratios of membrane area to channel void volume and feed reservoirvolume, provide conversions, exceeding 50%, and low processing times,less than five minutes while allowing high retentate recovery orpermeate recovery.

In accordance with another aspect of the invention a module for thefiltration of a liquid sample includes a housing with a feed port and aretentate port. The module also includes a filter comprising a singlepass tangential flow filtration (TFF) separation element comprising amembrane. The filter is disposed within the housing and includes atleast one flow channel having a flow channel inlet disposed at a firstend of the flow channel and coupled to the feed port, a flow channeloutlet coupled to the retentate port and disposed at a second oppositeend of the separation element. The housing further includes a permeateport which is fluidly coupled to the separation element and the housingis adapted to place the separation element in communication with avacuum source. The device can be coupled to a vacuum box or other vacuumsource. Such a device eliminates the need of a centrifuge to fractionatethe sample immediately and at the time of collection. In contrast toexisting devices that operate in dead-ended mode, this device usesexisting hollow fiber membranes configured to function in single passtangential-flow-filtration (TFF) mode. This enables significantincreases in permeation rates with corresponding reductions inprocessing times. Such a device enables in-situ fractionation of wholeblood and provides low cost and disposable devices for the recovery ofblood fractions according to the molecular-weight-cut-off of themembrane. Embodiments disclosed herein, recover at least 50% of plasma,free of cells and substantially free of hemolysis.

An integrated sample collection and fractionation device as disclosedherein, includes a housing, a separation element in the housing with atleast one flow channel. The flow channel has a flow channel inlet at afirst end of the flow channel, a flow channel outlet at a secondopposite end and a wall having a surface with an ultrafiltrationmembrane. The device further includes a feed compartment disposed withinthe housing and fluidly coupled to the flow channel inlet, an retentatecompartment disposed within the housing fluidly coupled to the flowchannel outlet, a integrated vacuum pressure source adapted to apply afirst vacuum pressure to the membrane disposed within the housing and apermeate compartment disposed within the housing and fluidly coupled tothe separation element. Such a device prepares samples for routine andadvanced clinical analysis, enables fractionation of blood sampleswithin a blood collection tube and without the need of centrifuges orother complex apparatus, resulting in faster, more reliable, lower costprocedures, improved capabilities for the blood collection, routineclinical testing, and molecular diagnostics of biomarkers.

The integrated sample collection and fractionation device combines novelfluidic and geometrical configurations with a self contained vacuum toprovide higher throughput and compatibility with robotic systems, lowercost devices for the purification and isolation of biological samples ina research setting in addition to the clinical setting, and thefeasibility disposable devices for sample processing. Such a device isuseful for the recovery of plasma, and the recovery of free drugs andfree hormones. A technique to fractionate a sample includes the stepsof: providing an integrated vacuum sample device comprising a singlepass TFF separation element having a flow channel, a vacuum tube havinga first end sealed with a septum adapted to receive a needle, a feedcompartment, retentate compartment and a permeate compartment,collecting the sample in the feed compartment, applying a first pressuredifferential between the feed compartment and the retentate compartment,the first pressure differential inducing tangential flow in the flowchannel, filtering the sample through the single pass TFF separationelement by applying a second pressure differential between the feedcompartment and the permeate compartment and collecting the permeate byinjecting a needle through the septum into the permeate compartment.Such a technique can collect a sample and makes readily available forsubsequent tests, and significantly reduce the time required for typicalclinical assays.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects, embodiments, objects, features andadvantages of the present teachings can be more fully understood fromthe following description in conjunction with the accompanying drawings.In the drawings, like reference characters generally refer to likefeatures and structural elements throughout the various figures. Thedrawings are not necessarily to scale, emphasis instead being placedupon illustrating the principles of the present teachings.

FIGS. 1A and 1B are schematic diagrams of 3-volume devices according tothe invention;

FIG. 2 is a schematic diagram of a 3-volume device similar to thedevices of FIG. 1A suitable for operation in a centrifuge;

FIG. 3 is a longitudinal cross section view of flow a channel formedwith hollow fiber membrane according to the present invention;

FIG. 4 is a longitudinal cross section view of a flow channel formedwith flat-sheet membranes according to the present invention;

FIGS. 5A and 5B are schematic diagrams of instrumented systemsincorporating the devices of FIGS. 1A and 1B;

FIG. 6A is a cross-sectional view of a 3-volume device including aseparation element comprising a hollow fiber membrane and suitable foruse in multi-well plates according to the present invention;

FIG. 6B is a cross-sectional view of the device of FIG. 6A, through line6B of FIG. 6A, showing further details of the separation element;

FIG. 7A is a cross-sectional view of a 3-volume device including aseparation element comprising spiral-wound membrane and suitable for usein multi-well plates according to the present invention;

FIG. 7B is a cross-sectional view of the device of FIG. 7A, through line7B of FIG. 7A, showing further details of the separation element;

FIG. 8 is a flow diagram illustrating the steps used to process a sampleand recover the retentate or permeate fractions using the devices ofFIGS. 1A, 1B, and 2;

FIGS. 9A and 9B are graphs of flux and conversion vs. time for Example1A;

FIGS. 10A and 10B are graphs of flux and conversion vs. time for Example1B;

FIGS. 11A and 11B are schematic diagrams of 2-volume devices includinghydrophobic vents according to the invention;

FIG. 12 is a schematic diagram of a 2-volume device similar to thedevices of FIG. 11A suitable for operation in a centrifuge;

FIG. 13 is a schematic diagram of 2-volume device including ahydrophobic vent in which the separation element is integrated into thepermeate reservoir according to the invention;

FIG. 14 is a schematic diagram of a 2-volume device in which the flowchannel carries the permeate to the permeate reservoir and theseparation element is integrated into the feed reservoir according tothe invention;

FIG. 15 is a flow diagram illustrating the steps used to process asample and recover the retentate or permeate fractions using the devicesof FIGS. 11A, 11B, and 12; and

FIG. 16 is a schematic diagram a 2-volume hollow fiber module suited forsmall volume samples where pressure differentials are induced bycapillary forces according to the invention;

FIG. 17 is schematic diagram of a vacuum driven device according to oneaspect of the invention;

FIG. 18 is an exploded schematic diagram showing further details of thevacuum driven device of FIG. 17;

FIG. 19 is schematic diagram of the vacuum driven device of FIG. 17operating with a vacuum box;

FIG. 20 is graph of predicted versus actual permeate recovery using thedevice of FIG. 18;

FIG. 21 is graph of permeate recovery versus processing time using thedevice of FIG. 18;

FIG. 22 is graph of permeate recovery versus processing time using thedevice of FIG. 18;

FIG. 23 is schematic diagram of a device similar to the device of FIG.23 including a separate vacuum port;

FIG. 24 is schematic diagram of an integrated blood collection deviceaccording to one aspect of the invention;

FIGS. 25A-25C show the operation of the device of FIG. 24;

FIG. 26 shows the completion of the operation of the device of FIG. 24;and

FIG. 27 is schematic diagram of an integrated blood collection andfractionation device similar to the device of FIG. 23 and having twoends sealed with septums.

DETAILED DESCRIPTION OF THE INVENTION

It has been discovered that the use of separation modules suitable forsample-preparation having long thin channels with relatively largeratios of channel membrane area to channel void volume, volume of asample feed reservoir, and volume of the feed sample, can yieldrelatively fast, high-conversion, low hold-up-volume, single-pass TFF(SPF) separations that can be driven with low pressures, compared toprior art devices. Some embodiments of the inventive module process feedsamples in a single-pass through the module without the need ofrecirculation loops by applying pressure differentials between pairs ofthe feed reservoir, a permeate reservoir and a retentate reservoir.Other embodiments process the sample using a module having a feedreservoir and a permeate reservoir, in conjunction with a hydrophobicvent.

Prior to further describing the invention, it may be helpful to anunderstanding thereof to set forth definitions of certain terms to beused herein. The expressions “analytical scale sample preparation,”“analytical sample preparation” and “sample-preparation” herein refersto applications where the sample volume is less than about 100milliliters, in various embodiments, less than about 10 milliliter, andin still various embodiments, less than about 1 milliliter. Theprocesses practiced in these applications are typically batch processes.

The terms “separation,” “fractionation” and “purification” herein referto the act of separating the feed sample into two streams, or fractions,permeate and retentate. The term “feed” and “feed stream” refer to thesolution being fed to the filter for its separation. The term “permeate”refers to the fraction of the feed that has permeated through themembrane; the permeate is the stream depleted of at least a portion ofthe retained species. The term “retentate” refers to the fraction of thesolution that has been retained by the membrane; the retentate is thestream enriched in the retained species. The term “conversion” is hereinused to denote the fraction of the feed volume that permeates throughthe membrane in a single-pass through the flow channels, expressed inunits of percentage of the feed stream volume. The term “recovery” willbe used to denote the mass fraction of the species of interest recoveredin the fraction of interest (permeate or retentate) expressed as apercentage of the mass contained in the feed sample.

The term “flux,” symbol J, is herein used to describe the rate ofpermeation of the solution within the flow channel through the membrane,expressed herein with the units of liters per hour per m² of membranearea and abbreviated as “lmh.” It is understood that the flux isidentical to the liquid velocity perpendicular to the surface of themembrane at the surface of the membrane, and that it varies along thelength of the channel, gradually decreasing along the flow direction ofthe channel from a high value at the proximal end (or feed end) of thechannel to a low value at the distal end (or retentate end) of thechannel. The expressions “specific membrane area of a flow channel,” and“specific membrane area of the channel,” are herein used synonymously todenote the amount of membrane area contained in the channel per unitchannel void volume which can be expressed in units of cm⁻¹, and isgiven by the ratio:

$\begin{matrix}{\sigma_{c} = {\frac{{Membrane}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Flow}\mspace{14mu}{{Channel}\;\left\lbrack {cm}^{2} \right\rbrack}}{{Void}\mspace{14mu}{Volume}\mspace{14mu}{of}\mspace{14mu}{Flow}\mspace{14mu}{{Channel}\;\left\lbrack {cm}^{3} \right\rbrack}}{in}\mspace{14mu}{units}\mspace{14mu}{{{of}\mspace{11mu}\left\lbrack {cm}^{- 1} \right\rbrack}.}}} & (1)\end{matrix}$

As used herein, ₁ represents the ratio of the membrane area of aseparation element (i.e., the membrane area of the channels of theseparation element) to the volume of the reservoir that includes thefeed sample. This ratio is referred to as the specific membrane area ofthe module and is given by:

$\begin{matrix}{\sigma_{1} = {\frac{{Membrane}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Separation}\mspace{14mu}{{Element}\mspace{14mu}\left\lbrack {cm}^{2} \right\rbrack}}{{Volume}\mspace{14mu}{of}\mspace{14mu}{Feed}\mspace{14mu}{{Reservoir}\mspace{14mu}\left\lbrack {cm}^{3} \right\rbrack}}{in}\mspace{14mu}{units}\mspace{14mu}{{{of}\mspace{11mu}\left\lbrack {cm}^{- 1} \right\rbrack}.}}} & (2)\end{matrix}$

It is understood that the reservoir including the feed sample isgenerally greater than or equal to the volume of the feed sample.

As used herein, _(M) represents the ratio of the membrane surface areaof separation element (i.e., the sum of the membrane area of thechannels) to the volume of the feed sample itself. This ratio, thespecific membrane area of the feed sample is defined by the followingequation:

$\begin{matrix}{\sigma_{M} = {\frac{{Membrane}\mspace{14mu}{Area}\mspace{14mu}{of}\mspace{14mu}{Separation}\mspace{14mu}{{Element}\mspace{14mu}\left\lbrack {cm}^{2} \right\rbrack}}{{Volume}\mspace{14mu}{of}\mspace{14mu}{Feed}\mspace{14mu}{{Reservoir}\mspace{14mu}\left\lbrack {cm}^{3} \right\rbrack}}{in}\mspace{14mu}{units}\mspace{14mu}{{{of}\mspace{11mu}\left\lbrack {cm}^{- 1} \right\rbrack}.}}} & (3)\end{matrix}$

It will be appreciated that the processing time for a sample is relatedto the flux, the desired conversion, the volume of the feed reservoir,the volume of the sample, and the parameters _(M) and ₁.

The expressions “transmembrane pressure differential,” “transmembranepressure” and “TMP” are herein used synonymously to describe the averagepressure differential between the flow channel, and the permeatecompartment, and given by:TMP=P _(F) −P _(P);  (4)

where

P_(F)=average of the pressure at the inlet and the outlet of the flowchannel; and

P_(P)=pressure at permeate compartment.

The expressions “transchannel pressure differential,” “transchannelpressure” and “TCP” are herein used synonymously to describe thepressure differential between the feed port to the retentate port asfollows:TCP=P _(inlet) −P _(R);  (5)

where

P_(inlet)=pressure at the inlet of the flow channel; and

P_(R)=pressure at retentate port. The pressure at the retentate port isessentially equivalent to the pressure at the outlet of the flowchannel. For most 2-volume devices, described below, P_(R) is thepressure at the end of the flow channel located distally from the inletof the flow channel.

The term “dimensionless length” is herein used to describe the productof channel length, L, and the specific membrane area of a flow channel,_(c), and is given by:λ=σ_(C) L  (6)

The dimensionless length of a separation element having more than onechannel is given by the sum of the dimensionless lengths of the channelsin a serial flow path of the separation element. Additionally, some ofthe embodiments described herein utilize SPF modules having longchannels, and more specifically, channels with high values ofdimensionless parameter, defined as follows:

$\begin{matrix}{\alpha = {L\sqrt{\frac{\sigma_{c}^{3}}{\sigma_{M}}}}} & (7)\end{matrix}$

The term “ultrafiltration membranes” and “UF membranes” are used hereinto refer to membranes that have pore sizes in the range between aboutone nanometer to about 100 nanometers. Such pore sizes, for example, canbe useful for the separation of polymeric molecules from water and otherlow molecular weight solutes. Molecules that are too large to penetratethese pores are retained while water, dissolved salts and smallmolecules can pass through these pores. The retention behavior forms thebasis for characterizing UF membranes, known as the “molecular weightcut off” of the membranes, and abbreviated as MWCO. In variousembodiments, the present invention utilizes ultrafiltration membraneshaving MWCO ratings in the range from about 1,000 Daltons to severalmillion Daltons.

The terms “hydrophobic vent” and “phobic vent” are used herein to referto a microporous element that, by virtue of the hydrophobicity of itsinterior surface and the small pore size of its porous structure, allowsthe venting of gases while preventing the permeation of an aqueousliquid through its porous structure. Hydrophobic vents are known tothose skilled in the art as elements useful for the reliable venting ofgases without the need of valves and the intervention of an operator.Phobic vents are not generally used at pressures exceeding the intrusionpressure of the microporous structure, which for example isapproximately 50 psi for elements having 0.2 μm pores.

As used herein the term “automatic” means performed without direct humanintervention. For example, an automatic apparatus automatically performsa method when a component of the apparatus, rather than a humanoperator, performs one or more steps of the method, even though a humanoperator might input instructions into the machine or even perform oneof the steps manually. Similarly, an “automated” method is a methodperformed automatically.

The inventive modules described herein can be provided in at least threeconfigurations. In a first configuration, the module comprises threereservoirs, for accepting the feed sample volume, and for the recoveryof the retentate and the permeate volumes, respectively; these areherein referred to as “3-volume” devices. In a second configuration, themodule comprises two reservoirs, for accepting the feed sample volume,and for the recovery of the permeate volume, respectively; these areherein referred to as “2-volume” devices. In a third configuration, themodule comprises a 2-volume configuration but with the flow channel influid communication with the permeate reservoir. In various embodiments,the present invention provides modules and methods for samplepreparation of single samples. In various embodiments the presentinvention provides modules and methods for the substantiallysimultaneous sample-preparation of a large number of samples suitablefor standard formats, as for example, multi-well plates and automatedsystems.

Ultrafiltration processes are used for concentration and diafiltrationof solutions, occasionally as adjuncts to reaction processes. In variousaspects of the present invention, the methods and modules can be used toconcentrate the retained species. According to this concentrationprocess, solvent is removed from the solution as well as any othersolute that permeates through the membrane. The result is theconcentration of those solutes that are retained by the membranes.Additionally, this concentration process purifies the retained speciesby the substantially simultaneous removal of those species that permeatethrough the membrane. In various aspects, the present invention providesmethods and devices for single pass TFF (SPF) processing. In variousembodiments, these methods and modules facilitate overcoming or eveneliminating one or more of the drawbacks associated with conventionalrecirculation TFF approaches when attempted at the sample prep scale.

The present invention relates to the separation and purification ofsubstances by membrane ultrafiltration, which is a pressure-drivenseparation process, and the driving forces to induce pressuredifferentials to effect the separation. SPF separations use two distinctpressure differentials: a first pressure differential to drive liquidflow tangentially along the surface of the membrane, the TCP, and asecond pressure differential to drive the permeation across themembrane, the TMP. Suitable driving forces and sources to induce thenecessary pressure differentials include, but are not limited to,centrifugal forces, compressed gases, vacuum sources, pumps, capillaryforces, osmotic forces, electro-osmotic forces and combinations thereof.

For many laboratory applications pressure and vacuum sources are themost convenient. For example, a compressed gas (a pressure source) maybe used to drive the feed solution, the same compressed gas at a lowerpressure connected to the retentate reservoir can be used to control theTCP, while the permeate is kept at atmospheric pressure. A vacuum sourcemay be used to drive the permeation by connecting a vacuum source,controlled at different vacuum levels, to the permeate and retentatereservoirs while the feed is kept at atmospheric pressure. In some casesit may be convenient to use both pressure and vacuum sources. There area wide variety of vacuum and pressure sources well known to thoseskilled in the art. For example, a vacuum source can be a water drivenaspirator or venturi, a central vacuum supply of the type commonly foundin laboratories, a dedicated vacuum pump, or combinations thereof. Adetailed list of means and devices for generating vacuums is given inPerry's Chemical Engineering Handbook, 6^(th) edition, McGraw-Hill,1984, at pp. 6-32 to 6-37. Suitable pressure sources include, e.g.,compressed gases from a cylinder with conventional means for regulatingthe applied pressure, using pressurized gas from a central sourcecommonly available in laboratories, using a dedicated compressor fromamong the types described, for example, in Section 6 of Perry's ChemicalEngineering Handbook, 6^(th) edition, McGraw-Hill, 1984, andcombinations thereof.

Another driving force suitable for laboratory applications can be thatbased on osmotic forces. Osmotic forces induce pressure differentials byvirtue of the difference in chemical composition of the solutions acrossthe membranes. Another driving force suitable for laboratoryapplications can be that based on capillary forces. Capillary forcesinduce pressure differentials by virtue of the surface energy of theliquid within the flow channels and the membrane pores. The size of thedriving force is inversely proportional to the size of the pores.Examples of embodiments that take advantage of capillary forces arediscussed in more detail in conjunction with FIG. 16.

In the various aspects of the present invention, a channel compriseswalls that are formed at least in part of an ultrafiltration membrane.While channels have a flow direction of liquid at any point of thechannel, it should be understood that the channels need not be straight.Channels can be straight, coiled, arranged in zigzag fashion, and ingeneral twist and turn in any spatial dimension. Channels can be open,for example, channels comprising hollow fiber membranes, or the channelscan have flow obstructions, for example, rectangular channels formed byflat-sheet membranes spaced apart by woven or non-woven spacers.

Another driving force suitable for laboratory applications can becentrifugal acceleration, provided by placing the module in a suitablecentrifugal field (e.g., in a laboratory centrifuge). In theseembodiments, the spatial location of the various components of themodule, feed reservoir, separation element, retentate reservoir andpermeate reservoir, should be in a definite order for the centrifugaldriving forces to effect the desired UF separation. It should be notedthat in centrifugal devices the tangential driving force is controlledindependently of the transmembrane driving force by the relativeplacement of the retentate and permeate reservoirs with respect to thefeed reservoir. There are a wide variety of centrifuges suitable forapplying a centrifugal acceleration for use in applying a driving forcefor the devices and methods of the present invention. Centrifugesinclude the “swinging bucket” or of the fixed bucket type, which areavailable for multi well plates as well as for single sample deviceswith acceleration levels of more than 1,000 g.

Referring to FIG. 1A, a sample preparation system 10 includes a 3-volumesample preparation module 100 comprising a housing 102, a separationelement 104 disposed within the housing 102 comprising a permeatecompartment 120 and at least one flow channel 106 having an inlet 110,an outlet 112 and a surface comprising a filtration membrane 108. Themodule 100 further comprises a feed reservoir 114 fluidly coupled to thechannel inlet 110 through a feed flow passage 120, a retentate reservoir116 fluidly coupled to the channel outlet 112 through a retentate flowpassage 122, and a permeate reservoir 118 fluidly coupled to theseparation element 104 through a permeate flow passage 124. The system10 further includes a feed pressure source 132 and a retentate pressuresource 134 coupled to the module 100. The module 100 additionallycomprises a feed port 126 coupled to the feed reservoir 114 and coupledto the feed pressure source 132, a retentate port 128 coupled to theretentate reservoir 116 and coupled to the retentate pressure source134, and a permeate port 136 coupled to the permeate reservoir 118.

In operation, the feed port 126 is used to introduce the feed sampleinto the feed reservoir 114 and then to connect the feed pressure source132 to the feed reservoir 114. The retentate pressure source 134 isconnected to the retentate reservoir 116, and the feed pressure is setto a higher pressure to provide positive pressure differentials betweenthe feed port 126 and the permeate port 136 and between the feed port126 and the retentate port 128. Here, the permeate reservoir 118 isvented to the atmosphere. The pressure differentials provide thenecessary driving forces for tangential flow by inducing the TCP and forpermeation by inducing the TMP. Timed application of these pressuredifferentials controls the conversion of the liquid sample volume in thefeed reservoir 114 into the retentate volume in the retentate reservoir116 and the permeate volume in the permeate reservoir 118. The pressuredifferentials are provided by combinations of pressure sources, vacuumsources, or by the application of centrifugal acceleration. In oneembodiment, the pressures provided by the pressure sources 132 and 134are lower than about 50 psi, in other embodiments lower than about 30psi, and yet other embodiments lower than 15 psi.

Now referring to FIG. 1B, in which like elements are provided havinglike reference designations as in FIG. 1A, a sample preparation system10′ includes a 3-volume sample preparation module 100′ similar to module100 of FIG. 1A and a pressure source 138 coupled to the permeatereservoir 118 via the permeate port 136. In addition, the feed reservoir114 is vented to the atmosphere instead of being coupled to feedpressure source 132. In one embodiment, pressure sources 134 and 138 arevacuum pumps which provide positive pressure differentials between thefeed port 126 and the permeate port 136 and between the feed port 126and the retentate port 128. Here, pressure source 138 provides astronger vacuum than pressure source 134. Table 1 lists some of thepossible embodiments and pressure source combinations according to theinvention, with configuration 1 corresponding to FIG. 1A andconfiguration 2 corresponding to FIG. 1B. In configurations 4 and 5 boththe TMP and TCP are controlled without venting any of the volumes to theatmosphere. This is desirable if exposure of the liquids to oxygen orwater vapor in the atmosphere is not desirable. If the liquid containsvolatile components then the use of configuration 4 avoids possiblevaporization.

In one embodiment, the specific membrane area of the module, ₁, isgreater than about 2 cm⁻¹ and in other embodiments greater than about 5cm⁻¹, and still another embodiment greater than about 10 cm⁻¹. Thechannels in some of these embodiments have specific membrane area of thechannel, _(c), greater than about 40 cm⁻¹, some greater than about 80cm⁻¹, and other embodiments greater than about 130 cm⁻¹ depending on thefeed stream and the membrane used for the separation. Generally theratio of _(c) to ₁ is greater than about 1, greater than about 3, andoften greater than about 10. This ratio affects the fraction ofretentate left in channel and therefore the hold up volume. Theseembodiments generally have a dimensionless parameter α greater thanabout 10,000. In one embodiment modules 100 and 100′ are used withsample volumes and have membrane areas such that the specific membranearea of the feed sample, _(M), is greater than about 2 cm⁻¹, in otherembodiments greater than about 5 cm⁻¹, and in still other embodimentsgreater than about 10 cm⁻¹. In these embodiments the ratio of _(M) to ₁is generally greater than about 1, greater than about 3, and oftengreater than about 10.

TABLE 1 MODULE PRESSURE SOURCES Pressure Configuration Feed PermeateRetentate Sources 1 Vented Pressure1 Atmosphere Pressure2 P1 > P2Permeate 2 Vented Feed Atmosphere Vacuum1 Vacuum2 V2 < V1 3 VentedPressure Vacuum Atmosphere Retentate 4 Un-vented A Pressure1 Pressure2Pressure3 P1 > P3 > P2 5 Un-vented B Vacuum1 Vacuum2 Vacuum3 V2 > V3 <V1 6 Sealed Pressure Atmosphere Sealed Retentate A 7 Sealed AtmosphereVacuum Sealed Retentate B 8 Centrifugal Atmosphere Atmosphere AtmosphereForce

Now referring to FIG. 2, in which like elements are provided having likereference designations as in FIG. 1A, a sample preparation system 10″includes a 3-volume sample preparation module 100″ similar to module 100of FIG. 1A. Here, the system 10″ does not include any directly coupledpressure sources. The feed reservoir 114, retentate reservoir 116 andpermeate reservoir 118 are vented to the atmosphere instead of beingcoupled to pressure sources. Here the driving forces are provided by acentrifuge (not shown) with a centrifugal acceleration vector indicatedby arrow 140. The feed reservoir 114, the retentate reservoir 116 andthe permeate reservoir 118 are juxtaposed along the centrifugalacceleration vector 140, the retentate reservoir 116 interposed betweenthe feed reservoir 114 and the permeate reservoir 118. In one embodimentas shown in FIG. 2, the retentate reservoir 116 and the permeatereservoir 118 can overlap on an axis perpendicular to the centrifugalacceleration vector 140. The embodiment of FIG. 2 corresponds toconfiguration 8 in Table 1.

In operation, the centrifuge provides the pressure differential drivingforces. The location and orientation of the three reservoirs 114, 116and 118 and the separation element 100″ with respect to the centrifugalacceleration vector 140 determine the TCP and TMP. In variousembodiments, the relative location of the separation element 100″ andthe retentate reservoir 116 provides the ability to control induced TCPsubstantially independently of the induced TMP. The local pressure insystem 10″ is set by the liquid position relative to the location of theliquid level in the feed reservoir multiplied by the centrifugalacceleration vector. Hence the placement of the retentate reservoir 116closer to the feed reservoir 114 insures the TCP is controlledindependently of the TMP, which is set by the distance between theliquid level in the feed reservoir 114 and the liquid level in thepermeate reservoir 118 along centrifugal acceleration vector.

The ports 126, 128 and 136, and flow passages 120, 122 and 124 aredepicted to illustrate one embodiment for adding and removing liquids aswell as venting to the atmosphere and are not intended to limit theinvention in any way. Depending on the application, vacuum and otherpressure sources are optionally connected to the ports 126, 128 and 136to induce the pressure differentials necessary to drive the process.

Separation elements are preferably composite structures comprising flowchannels for directing the feed, retentate and permeate as well as otherelements to support the separation process. The present inventionutilizes separation elements made with ultrafiltration membranes.Ultrafiltration membrane structures can be described by three broadstructural categories: tubular, sheet and monolithic. Hollow fibermembranes are a kind of tubular UF membrane, with an inner diameter oftypically between 0.1 and 1.0 millimeters whose inner surface is theseparating membrane. In various applications, the feed solution to beprocessed flows through the inside of the hollow fiber membrane,hereafter referred to as the “lumen,” and the permeate leaves on theoutside of the fibers.

Sheet membranes can be made in various forms and typically are laminatedto some sort of cloth support. Two sheets of membrane separated by ahighly permeable net-like structure, or spacer, forms the flow channel.A wide variety of sheet membranes can be used in various embodiments ofthe present invention, including, but not limited, non-planar sheets andmonolithic membranes. For example, membranes with undulating, dimpled orcorrugated surfaces are examples of non-planar sheet membranes.

In various aspects, the modules of the present invention includeseparation elements made of conventional ultrafiltration membranes inany of the multiple topologies available. FIG. 3 schematically depicts aflow channel using hollow fiber membranes, while FIG. 4 schematicallydepicts a flow channel using flat-sheet membranes.

Now referring to FIG. 3, an exemplary hollow fiber separation element104′ similar to the separation element 104 of FIG. 1A includes a housing142 and a hollow fiber ultrafiltration membrane 148 disposed within thehousing 142. The membrane 148 forms a flow channel 146. The module 104′further includes seals 154 disposed adjacent a channel inlet 150 and achannel outlet 152 to separate the feed stream in the channel 146 fromthe permeate compartment 144. In operation, the feed enters the flowchannel 146 at the channel inlet 150, flowing tangentially over themembrane 148 towards the channel outlet 152, driven by, for example, atranschannel pressure differential, TCP, and a transmembrane pressuredifferential, TMP, generated by at least one pressure source (notshown). As a result of the TMP a portion of the feed permeates throughthe membrane 148 as indicated by flow arrows providing the permeate inthe permeate compartment 144. The flow channel 146 formed by the hollowfiber membrane 148 can be further described by its length, L, and lumendiameter, d, as shown in FIG. 3. Flow channels formed with hollow fibermembranes are typically open with no flow obstructions. The specificmembrane area, σ_(C), of the flow channel 146 is defined as the ratio ofthe membrane area contained in the channels divided by the void volumeof the channel 146. For channels formed with hollow fiber membranes thespecific membrane area of the flow channel is derived from equation 1as:

$\begin{matrix}{\sigma_{C} = {\frac{4}{d}.}} & (8)\end{matrix}$

In one embodiment, the flow channel 146 has a specific membrane areagreater than about 50 cm⁻¹, and in this embodiment the membrane has ahydraulic permeability greater than about 2 lmh/psi. In anotherembodiment the specific membrane area is greater than about 80 cm⁻¹, andin yet another embodiment the specific membrane area is at least about130 cm⁻¹. High specific membrane areas result in higher flux and reducedhold-up-volume of the SPF module. For hollow fiber channels thedimensionless length is given by:

$\begin{matrix}{\lambda = {4\mspace{11mu}{\frac{L}{d}.}}} & (9)\end{matrix}$

In one embodiment the dimensionless length, λ, of the flow channel of amodule comprising hollow fiber flow channels is greater than about2,000, in another embodiment greater than about 4,000 and in yet anotherembodiment greater than 10,000. The values of specific membrane area,σ_(C), and dimensionless length, λ, in these embodiments enable thehollow fiber module 104′ to function effectively in a SPF samplepreparation process similar to the process described below inconjunction with FIG. 8. In one embodiment the ratio of the membranearea of the separation element to the volume of the feed reservoir, σ₁,is greater than about 2 cm⁻¹.

Referring to FIG. 4, an exemplary flat-sheet separation element 104″similar to the separation element 104 of FIG. 1A includes a housing 162and a flat-sheet ultrafiltration membrane 168 disposed within thehousing 162. The membrane 168 forms a flow channel 166 supported by aspacer 160 interposed between two surfaces of the membrane 168. Themodule 104′ further includes seals 154 disposed adjacent a channel inlet150 and a channel outlet 152, to separate the feed stream in the channel146 from the permeate compartment 144. In one embodiment, channel 166 isformed by sandwiching the spacer 160 between two sheets of flat-sheetmembrane 168. Channel 166 formed in this manner is referred to as arectangular channel since it possesses a rectangular cross-section,although it is to be understood that SPF channels are not limited torectangular cross-sections or any specific topology.

In operation, the feed stream enters the flow channel 166 at the channelinlet 170, flowing tangentially over the membrane 168 towards thechannel outlet 172, driven by, for example, a transchannel pressuredifferential, TCP, and a transmembrane pressure differential, TMP,generated by at least one pressure source (not shown). As a result ofthe TMP a portion of the feed permeates through the membrane 168 asindicated by flow arrows providing the permeate in the permeatecompartment 164. The flow channel 166 formed by the flat sheet membrane168 is further described by its length, L, and height, h, as shown inFIG. 4. The feed stream can be distributed across the width of thechannel 166 by appropriate feed distributors (not shown). The retentatecan be collected along the width of the channel 166 by appropriateretentate distributors (not shown). The spacer 160 maintains themembranes in a spaced apart arrangement, and edge seals 174 enclose thechannel 166 and form a portion of the permeate compartment 164. Thereare numerous techniques for forming edge seals known to those skilled inthe art. The spacer 160 can be a woven, non-woven, or molded structure,or combinations thereof, that allow the percolation of liquid betweenits solid structures but are also sufficiently rigid to maintain thechannel height h when exposed to compressive loads. The “void fraction”of the spacer 160, ε, defined as the ratio of the void volume containedwithin the spacer to the total volume occupied by the spacer 160, andthe structure of the spacer 160 affects the void volume as well as thehydraulic resistance of the channel 166. In one embodiment the spacer160 is a turbulence-promoting spacer.

The calculation of the specific membrane area, σ_(c), and thedimensionless length λ, can be provided for a specific channel topologyusing the channel height h, and void fraction. For example, forrectangular channels, the specific membrane area of the channel isderived from equation 1 as follows:

$\begin{matrix}{{\sigma_{C} = \frac{4}{ɛ\mspace{11mu} h}};} & (10)\end{matrix}$where:h is the height of the channel; andε is the void fraction of the spacer.The dimensionless length, λ, is derived from equation 5 as follows:

$\begin{matrix}{{\lambda = {2\mspace{11mu}\frac{L}{ɛ\mspace{11mu} h}}};} & (11)\end{matrix}$where:L is the length of the channel;h is the height of the channel; andε is the void fraction of the spacer.

Specific formulas for these parameters for channels having alternativetopologies can be derived from the dimensions of the channel 166 or canbe computed empirically as is known in the art. In one embodiment, thechannel 166 has a specific membrane area greater than about 40 cm⁻¹ andin another embodiment the channel 166 has a specific membrane areagreater than about 80 cm⁻¹.

Now referring to FIG. 5A, in which like elements are provided havinglike reference designations as in FIG. 1A, an instrumented samplepreparation system 230 includes a 3-volume sample preparation module 190similar to module 100 of FIG. 1A. System 230 further includes a pressuresource 202, here, a source of compressed nitrogen gas N₂, a pressureregulator 204 coupled to the pressure source 202, coupled to feed andretentate pressure regulators 206 and 210. The feed pressure regulator206 is coupled to a precision pressure gauge 208, and 206, and retentatepressure regulator 206 is coupled to a precision pressure gauge 212. Inone embodiment, feed and retentate reservoirs 114 and 116 comprised ⅛″and 1/16″ ID clear Tygon tubing, respectively. The system 200 alsoincludes valve 216 (e.g., a pinch valve) installed on feed port 126 andvalve 214 (e.g., a pinch valve) installed on retentate port 128. Thevarious embodiments of separation element 194 are described below inconjunction with Examples 1-5.

In operation, the main system pressure is regulated with pressureregulator 204 and the feed and retentate pressures are preciselycontrolled by means of the precision pressure regulators 206 and 210,here for example, 0-30 psi, 20-turn pressure regulators, and monitoredby pressure gauges 208 and 212, here 0-30 psi, digital gauges with 0.01psi resolution. Initially the permeate reservoir 118, here directed to awaste container (not shown) is maintained at atmospheric pressure,therefore the inlet TMP is equal to the feed pressure measured at gauge205, and the TCP is controlled to the desired value by means of pressureregulator 210 where TCP=P_(F)−P_(R). The progress of the ultrafiltrationsample processing is monitored by measuring the length of the liquidcolumn in the reservoirs, the feed reservoir 114 containingapproximately 80 microliters per centimeter of length and the retentatereservoir 116 containing approximately 20 microliters per centimeter oflength. It is understood that some or all of these operations can beperformed manually or the steps could be automated. An automatedembodiment (not shown) includes but is not limited to a programmablecontroller to control pressure differentials and timing, volume sensors,flow sensors, and concentration sensors.

Now referring to FIG. 5B, in which like elements are provided havinglike reference designations as in FIG. 1B, an instrumented samplepreparation system 230 includes a 3-volume sample preparation module 192similar to module 100′ of FIG. 1B. System 230 includes a vacuum source232 as a first pressure source, here, a vacuum pump was capable ofgenerating vacuums exceeding 29 in-Hg. Since no attempt was made toregulate the vacuum, (i.e., the vacuum pump was connected directly topermeate pinch valve 236), the vacuum can be considered to be a fullvacuum. System 230 further includes a gravity siphon 240 as a secondpressure source. The operation of system 230 is described below inconjunction with Examples 3 and 4.

Referring to FIG. 6A, a 3-volume module 250 comprises a housing 252, ahollow central core 266 having a plug 258 and forming a retentatereservoir 268, disposed within the housing 252. The housing 252including a housing wall 254 and a portion of the central core 266 forma feed reservoir 262. The module 250 further comprises a permeatereservoir 276, a retentate port 264 for connecting a pressure source(not shown) to the retentate reservoir 268 and a permeate port 280 forconnecting a pressure source (not shown) to the permeate reservoir 276.The module 250 further comprises a separation element 274 surrounding aportion of the central core 266. The separation element 274 comprises aflow channel 284 comprising a hollow fiber membrane, a flow passage 270fluidly coupling the feed reservoir 262 to a proximal end 272 of theflow channel 284. A distal end 282 of the flow channel 284 is fluidlycoupled to the retentate reservoir 268 by a flow passage 288. In oneembodiment, the permeate reservoir 276 is located below the separationelement 274, thereby receiving the permeate by virtue of gravity. Inthis embodiment, the permeate reservoir 276 is optionally detachablefrom the housing 252 by means of a mating flange 286 coupled to thehousing wall 254 to enable the transport of the permeate separately fromthe rest of the module.

In operation, the feed sample in introduced into the feed reservoir 262,a first vacuum source (not shown) is connected via port 264 to theretentate reservoir 268, while a second vacuum source (not shown) isconnected via port 280 to the permeate reservoir 276, the second vacuumsource providing a more negative pressure that the first vacuum source.The separation element 274 comprises in one embodiment a single hollowfiber in wound around the central core 266. In one embodiment, thehollow fiber has a lumen diameter of about 200 micrometers, resulting ina value of _(C) of about 200 cm⁻¹. The separation element 274 in thisembodiment has a surface area of about 3 square centimeters and thevolume of feed reservoir 262 is about 100 microliters, resulting in avalue of ₁ of about 30 cm⁻¹. It will be appreciated that more that oneflow channel 284 could be included in separation element 274 and thatthe flow channels could be coupled serially to provide additionalmembrane surface area.

Although embodiments utilizing vacuum sources are described, it is to beunderstood that embodiments utilizing pressure sources are alsopossible. In various embodiments, the permeate reservoir is atatmospheric pressure and the first and second pressure sources areconnected to the feed and retentate reservoirs, respectively. Thisconfiguration advantageously provides a long thin channel (e.g., λgreater than about 2,000) in a compact device. An array of modules 250can also be used in an automated sample processing system (e.g., amulti-well plate device) using sample handling techniques known in theart.

Now referring to FIG. 6B, in which like elements are provided havinglike reference designations as in FIG. 6A the module 250 furthercomprises a support ring 290 connecting to the central core 266 and asupport seal 292 which connects to the housing wall 254. The permeateport 280 passes through the support seal 292 which is connected to thesupport ring 290 and the housing wall 254. The flow passage 270 fluidlycoupling the feed reservoir 262 to the proximal end 272 of the flowchannel 284 passes through the support ring 290.

Now referring to FIG. 7A, in which like elements are provided havinglike reference designations as in FIG. 6A, a 3-volume module 260 similarto module 250, comprises a separation element 274′ comprising a flowchannel 284′ comprising a flat-sheet membrane in a spiral-woundconfiguration instead of the hollow fiber membrane of separation element274. Module 260 includes permeate ports 280′ coupled directly to apermeate reservoir 276′ for connecting a pressure source (not shown) tothe permeate reservoir 276′. The spiral-wound separation element 274′comprises a single leaf comprising a rectangular channel formed withspacers having a channel height of about 100 micrometers and a porosityof about 0.7, resulting in a value of _(C) of about 285 cm⁻¹. In oneembodiment, the separation element 274′ has a surface area of about 4.5square centimeters and the volume of feed reservoir 262 is about 100microliters, resulting in a value of ₁ of about 45 cm⁻¹.

In operation, the feed enters the proximal end of flow channel 284′through flow passage 272′. The flow spirals inwardly until it reachesthe distal end of the flow channel 284′, at which point it enters theretentate reservoir 268 through flow passages 282′. In one embodiment,the permeate reservoir 276′ is at atmospheric pressure and first andsecond negative pressure sources (e.g., vacuum sources) are coupled tothe feed reservoir 262 and retentate reservoir 268, respectively. WhileFIG. 7A represents an embodiment driven by vacuum sources, it isunderstood that embodiments utilizing positive pressure sources are alsopossible.

It is understood that the sample processing using modules 250 and 260driven by positive pressure or negative pressures can utilize pumps toprovide positive pressure and vacuums to provide negative pressures. Forexample, a peristaltic pump, automated pneumatic and electric ormanually operated syringe pumps may be advantageously used to generateboth pressures. In certain embodiments, the feed and retentatedisplacement volumes determine the conversion. To operate modules 250and 260 in such a “fixed conversion” mode, the feed sample is loadedinto a large syringe pump (not shown) coupled to the proximal end offlow channels 284 and 284′, respectively, and a smaller syringe pump(not shown) is fluidly coupled to the distal end of flow channels 284and 284′, respectively. In this manner, the displacement volumes of thelarge and small syringe pumps can become the feed and retentate volumes,respectively, integrated into modules 250 and 260 to induce the pressuredifferentials.

Now referring to FIG. 7B, in which like elements are provided havinglike reference designations as in FIG. 7A the module 260 furthercomprises a support ring 290′ connecting the housing wall 254′ to thecentral core 266. The flow passage passes through the support ring 290′which provides a seal at the end of the spiral wound separation element274′. In addition, the permeate ports 280′ are coupled directly to apermeate reservoir 276′ by a support seal (not shown).

Turning now to FIG. 8, a flow diagram illustrates a process forprocessing a sample and recovering either the retentate fraction or thepermeate fraction using 3-Volume devices. In the flow diagrams of FIGS.8 and 15, the rectangular elements are herein denoted “processingblocks” (typified by element 302 in FIG. 8) and represent manualprocessing steps. Alternatively, the processing blocks represent stepsperformed by functionally equivalent automated equipment. It will beappreciated by those of ordinary skill in the art that some of the stepsdescribed in the flow diagrams may be implemented automatically whileothers may be implemented in a different manner (e.g. via a manualprocedure) and that both positive pressure source and negative pressure(e.g., vacuum) sources can be used in SPF sample processing, bothpositive and negative pressure sources collectively referred to pressuresources. It will also be appreciated by those of ordinary skill in theart that unless otherwise indicated herein, the particular sequence ofsteps described is illustrative only and can be varied without departingfrom the spirit of the invention. The systems 10 and 10′ of FIGS. 1A and1B, respectively, are used in the description of the exemplary methods.

The process commences in step 300, following which a predeterminedvolume of sample is supplied into the feed reservoir 114 at step 302. Instep 304 the feed and retentate reservoirs 114 and 116 (or alternativelythe feed and permeate reservoirs 114 and 118) are connected to two ofthe pressure sources 132, 134 and 138. It is understood that eitherpositive pressure sources, for example, pumps or pressurized gas can beused or alternatively vacuum sources can be used as described in TableI.

In step 306, the first pressure differential is applied, and in step308, the second pressure differential is applied. In one embodiment,both pressure differentials are applied substantially simultaneously.The pressure differentials induce a positive and controllable TMP andTCP. If feed displacement is used as a means of recovering the residualliquid within the flow channel, processing continues at step 330otherwise, processing of the sample continues in step 310 until thesample is substantially consumed and the desired conversion is achieved.In one embodiment, substantial consumption is about 95% consumed. Theprocessing time is proportional to _(M) and, in one embodiment, _(M) isgreater than about 2 cm⁻¹. Although in one embodiment the pressuredifferentials are adjustable, it is not required that the pressuredifferentials be changed during the process. In some embodiments theratio of _(M) to ₁ is greater than about 1, greater than about 3, andoften greater than about 10.

In step 312, the pressure differentials are dissipated by substantiallyreducing to zero the applied pressures, disconnecting, or shutting offthe first and second pressure sources. One of several possible methodsare then used to recover the permeate fraction or retentate fraction.The method is selected, for example, based on simplicity and degree ofrecovery desired. In step 314, the permeate fraction is directlywithdrawn from the permeate reservoir 118 and the process is finished instep 340. In step 316, the retentate fraction is directly withdrawn fromthe retentate reservoir 116 and the process is finished in step 340.Withdrawal of the samples can be accomplished by means of a manual orautomatic syringe or pipette, or alternatively by pouring the contentsof the reservoir into another container.

In step 320, the retentate is utilized as the displacement medium byinducing a reverse flow by applying a small negative TCP after the feedsample is substantially consumed. The negative TCP causes the retentateto flow toward the feed reservoir 114 thereby displacing the residualfluid within the flow channel 106 towards the feed reservoir 114. Theresidual liquid, together with the retentate (the displacement medium)is collected in the feed reservoir 114 (where further optionalprocessing steps can occur) and withdrawn in step 322 and the process isfinished in step 340. The optional processing steps include subjectingthe recovered permeate and retentate fractions to chemical or physicalprocessing steps and in-situ analysis before withdrawal.

In step 324, a small volume of a buffer solution is utilized (e.g., abuffer chase) as the displacement medium. A buffer solution isintroduced into the feed reservoir 114 after the feed sample issubstantially consumed, followed by the application of a small positiveTCP to displace the residual fluid within the flow channel 106. Theresidual liquid, together with the buffer displacement medium iscollected in the retentate reservoir 116, in step 336. In step 328, theretentate is withdrawn from the retentate reservoir 116. In analternative embodiment, the buffer chase is introduced into theretentate reservoir, followed by the application of a small negative TCPto collect the residual liquid and buffer chase in the feed reservoir114.

In step 326, the permeate is utilized as the displacement medium byinducing reverse permeation by applying a third pressure differentialbetween the permeate and retentate reservoirs to induce a small negativeTMP after the feed sample is substantially consumed. The negative TMPcauses a small amount of permeate to flow into the interior of the flowchannel thereby displacing the residual fluid within the flow channel106 by reverse permeation. The residual liquid, together with the smallamount of permeate displacement medium is collected in the retentatereservoir 116 and withdrawn in step 328 and the process is finished instep 340. In an alternative embodiment, an osmotic pressure differentialexisting between the permeate and the residual liquid can be used toinduce reverse permeation without the application of a negative TMP. Inanother alternative embodiment, the residual liquid, together with thesmall amount of permeate displacement medium is collected in the feedreservoir by applying a third pressure differential between the permeateand feed reservoirs.

The feed displacement method proceeds in step 330, where a small amountof the remaining feed sample is utilized as the displacement medium. Thepermeation process is stopped before the feed sample is fully consumedby reducing the pressure differentials while there is still some feedsample left in the feed reservoir. In step 332, the pressuredifferentials are dissipated by disconnecting or shutting off the firstand second pressure sources. In step 334, a small flow displaces theresidual liquid within the channel towards the retentate reservoir 116.The flow is induced by applying a small positive TCP. The residualliquid, together with the residual feed sample displacement medium iscollected in the retentate reservoir 116 in step 336 and withdrawn fromthe retentate reservoir 116 in step 328. The process finishes in step340.

From the foregoing, it can be appreciated that the modules and methodsof the invention facilitate sample processing using SPF operation. Theinvention will be further described in the following examples, which arenot exhaustive and do not limit the scope of the invention described inthe claims.

EXAMPLES 1A AND 1B

The following two examples illustrate experiments in which pressuresources were used to drive the filtration using the instrumented samplepreparation system similar to system 200 of FIG. 5A.

Test Solutions

A bovine serum albumin (BSA) solution was prepared at a concentration of10 mg/ml in 0.025 M Tris-HCl Buffer adjusted to pH 7.6. All experimentswere conducted at room temperature. The BSA was obtained fromSigma-Aldrich, catalog number A-3294.

SPF Modules

SPF modules 190 were made with separation elements 194 comprising hollowfiber membranes. Hollow fiber membranes were polysulfone with a 10,000MWCO. The separation elements 194 were constructed by potting the hollowfiber membranes into a ⅛″ ID clear Tygon™ tubing with a 5-minute epoxy.Modules were made with varying lengths and varying number of polysulfonehollow fiber membranes. Separation elements had two permeate ports (thesecond port not shown) to allow effective flushing of the permeatecompartment. Permeate ports were located within 1 cm of the pottedregions to minimize dead volume. Prior to testing, all separationelements were pre-treated and integrity tested as follows:

1. flushed with 1 ml of a 60/40 ethanol/DI-water solution to assurecomplete wetting;

2. thoroughly flushed with DI-water;

3. integrity tested at 25 psi with compressed N₂ using the test set-updescribed below; and

4. flushed with 0.025 M Tris-HCl buffer.

Test Set-Up

The test system 230 was configured as illustrated in FIG. 5A. CompressedN₂ was used as the pressure source 202, the main system pressureregulated with a conventional 0-50 psi pressure regulator 204. Feed andretentate pressures were precisely controlled by means of precisionpressure regulators 206 and 210 (0-30 psi, 20-turn pressure regulators),and monitored by precision digital pressure gauges 208 and 212 (0-30psi, 0.01 psi resolution). The permeate compartment was maintained atatmospheric pressure, while the retentate valve 214 is closed, thereforethe test TMP was equal to the feed pressure 208.

Feed and retentate reservoirs comprised ⅛″ and 1/16″ ID clear Tygontubing, respectively. The progress of the ultrafiltration experiment wasmonitored by measuring the length of the liquid column in thereservoirs, the feed reservoir 114 containing approximately 80microliters per centimeter of length and the retentate reservoir 116containing approximately 20 microliters per centimeter of length. Theretentate was collected at the end of the run in 5 milliliter, pre-taredsample vials, followed by UV assay to determine protein concentration.

Protein Determination

A tabletop UV spectrophotometer, Bausch & Lomb Model Spectronic 21 at280 nm was used to measure the protein concentration in the feed sample,and in the retentate and permeate fractions. This data was used todetermine the concentration factor (ratio of retentate to feedconcentration) and the BSA recovery in the retentate (ratio of retentateto feed BSA mass). Multiple dilutions (10:1, 20:1 and 50:1) wereconducted on feed and retentate samples, as necessary, to obtain UV specreadings between 0.500 and 1.500 Absorbance Units (AU), and preferablybetween 0.500 and 1.000 AU. Depending on the sample volume available, 1cc or 3 cc cuvettes were used.

Test Procedure

The following steps were used in conjunction with examples 1-4 describedbelow:

1. Shut feed port 126 and retentate port 128 using pinch valves 216 and214, respectively;

2. Set feed and retentate pressures using regulators 206 and 210;

3. Disconnect graduated feed reservoir 114 and introduce BSA sampleusing 5 ml BD syringe directly into the disconnected feed reservoir 114;

4. Reconnect feed reservoir 114;

5. Unclamp retentate pinch valve 214 and feed pinch valve 216substantially simultaneously to start ultrafiltration;

6. Measure feed and retentate liquid columns in respective reservoirs114 and 118 as a function of time using a stop watch; continue untilfeed reservoir 114 is emptied;

7. Clamp retentate pinch valve 214 when retentate liquid column startsto accelerate (this happens when the feed liquid column becomes depletedat end of the run);

8. Clamp feed pinch valve 216 soon thereafter;

9. Disconnect feed reservoir 114 (to dissipate pressures); thenreconnect;

10. Disconnect retentate reservoir 116;

11. Collect retentate by displacing it with N₂ into a pre-tared samplevial;

12. Flush module with 2 ml buffer between runs; and

13. Measure BSA concentration of retentate.

In some experiments the retentate was collected in the retentatereservoir, in others in the feed reservoir. In some cases, a bufferchase was used to displace the residual liquid within the flow channel.In examples 1A and 1B an SPF module with 135 μm hollow fiber membranesin a 3-volume device similar to the sample preparation module 190 ofFIG. 5A was used with positive pressure sources to drive a single-passultrafiltration. These examples illustrate the concentration of 10 mg/mlBSA using 10,000 MWCO hollow fibers with lumen diameter of about 135 μmand 27.5 cm long. The hollow fibers were obtained from SpectrumLaboratories, Rancho Domingo, Calif. The separation element 194 used inthe SPF module 192 comprised a bundle of 10 hollow fiber membranes,having a total membrane area of about 11.7 cm². The feed streamcomprised 5 ml of BSA solution. The feed pressure was about 14.60 psi,and the retentate pressure was about 13.05, resulting in a TCP of about1.55 psi. The retentate was recovered in the feed reservoir; no bufferchase was used. The total retentate mass was about 0.9166 g,corresponding to a conversion of 82%. FIGS. 9A and 9B summarize thedata. The flux 342 and the volume of the feed sample 344 are shown as afunction of time in FIG. 9A, and the feed flow rate 350 and retentateflow rate 352 as a function of time in FIG. 9B.

A second run identical to the first was conducted, except that the TCPwas lowered to 1.13 psi, and the retentate was collected in theretentate reservoir. The total retentate mass was about 0.4879 g,corresponding to a conversion of 90%. FIGS. 10A and 10B summarize thedata. The flux 360 and the volume of the feed sample 362 are shown as afunction of time in FIG. 10A, and the feed flow rate 368 and retentateflow rate 370 as a function of time in FIG. 10B.

High steady-state fluxes of 21.7 and 14.9 lmh, respectively, wereobtained. Also, as shown in FIGS. 9A, 9B, 10A and 10B, steady state wasreached within about 2 minutes, which compares favorably with acalculated transient time of about 1.3 minutes. It was observed that thesystem pressure was controllable to ±0.02 psi, and, as expected, theconversion can be readily controlled with TCP, the higher the TCP thelower the conversion. A comparative summary of the two runs is shown intable 2 below.

TABLE 2 Example TCP V₀ Steady State Retentate Conversion # [psi] [cm/s]Flux [1 mh] Mass [g] [%] 1A 1.55 5.54 21.7 0.9166 82% 1B 1.13 4.23 14.90.4879 90%

Table 3 below summarizes the parameters for these two runs. The hollowfiber module had a specific membrane area of the channel, _(C), of 148cm⁻¹ and a dimensionless length of 4,070. The process was operated at aspecific membrane area of the sample, _(M), of 2.33 cm⁻¹ for both runs1A and 1B. Here ₁ was approximately equal to _(M), because the feedreservoir was full.

TABLE 3 Example Time c M # [min] [cm⁻¹] [cm⁻¹] [ ] 1A 10.5 148 2.334,070 1B 14.3 148 2.33 4,070

EXAMPLES 2A, 2B AND 2C

The following examples compare SPF UF processing with 600 μm hollowfiber (HF) Membrane to prior art centrifugal devices to demonstrate theslower performance of prior art centrifuge techniques for processing oflaboratory scale samples. Examples 2A and 2B provide data on a method ofprocessing of a 3-volume embodiment of the present invention utilizingpressure sources to drive the single-pass ultrafiltration. Theseexamples illustrate the concentration of 10 mg/ml BSA using 10,000 MWCOhollow fibers with lumen diameter of about 600 μm and 155 cm long. Incontrast, Example 2C provides data on a method of the prior artutilizing a centrifugal device, Microcon 30, manufactured by MilliporeCorp., Billerica Mass., USA.

In examples 2A and 2B, the separation element used in the SPF modulecomprised a single hollow fiber membrane, having a membrane area ofabout 29 cm². The feed stream comprised of about 5 ml of BSA solution(exact weight shown in Table 4 below); the feed pressure was about 13.6psi; the retentate was recovered in the retentate reservoir; and abuffer chase of about 0.5 ml, introduced as described in step 324 ofFIG. 8, was used to displace the residual liquid.

In example 2C, the Microcon 30 centrifugal UF device has a circularflat-sheet membrane, with a MWCO of 30,000 Daltons and area of about0.34 cm². The feed stream comprised about 0.5 ml of BSA solution (exactweight shown in table below); the centrifuge (VWR Scientific Model V)was spun at a velocity of 9,500 RPM, generating an acceleration of about5,000 g; the retentate was recovered following the recommendedprocedure, namely, by inverting the feed reservoir (containing the UFmembrane) and collecting it in an eppendorf tube; and a buffer chase ofabout 0.064 ml, added to the feed reservoir and recovered in the samemanner as the retentate, was used to displace any residual liquidremaining on the surface of the membrane.

The data from all 3 experiments is summarized in Table 4 below.

TABLE 4 Example 2A Example 2B Example 2C Membrane Area [cm²] 29 29 0.34Mass of Feed Solution [g] 4.98 5.18 0.485 Feed Pressure [psig]/[g′s]13.6 13.6 5,000 g TCP [psi] 0.40 1.00 — Permeation Time [min] 7.5 5.522.0 Conversion [%] 94.1 93.3 94.1 (Including Buffer Chase) Recovery [%]85.1 83.7 92.6 (Retentate Only) Recovery [%] 95.8 94.7 93.4 (Retentate +Buffer Chase) Permeate Loss [%] — 0.8 2.4 Average Flux [1mh] 13.3 18.712.4

The SPF module 190 processed the sample in less than 10 minutes comparedto more than 20 minutes for the prior art centrifugal device; thisdifference is believed to be due to the high _(M) of about 6 cm⁻¹ forthe SPF embodiment as compared to a _(M) of less than 1 cm⁻¹ for theprior art centrifugal device. All devices yielded very high BSArecovery, exceeding 90%. Table 5 below summarizes other method anddevice parameters for these three runs. Note that for the prior artdevice _(C) and are undefined since these devices do not have flowchannels.

TABLE 5 Example Time c M # [min] [cm⁻¹] [cm⁻¹] [ ] 2A  7.5 67 5.8 10,3002B  5.5 67 5.6 10,300 2C 22.0 — 0.7 —

EXAMPLES 3 AND 4

The descriptions of the methods and modules used in examples 1 and 2apply to examples 3 and 4, except that vacuum sources were used to drivethe permeation instead of positive pressure sources. The test set up wasaccordingly modified as described below. The procedure outlined inexamples 1 and 2 was followed with minor adjustments to account for theuse of vacuum sources instead of pressure sources.

Test Set-Up

A system similar to system 230 was used for examples 3 and 4 as shown inFIG. 5B. A vacuum pump 232 was used as the vacuum source coupled to thepermeate port. The vacuum pump 232 was capable of generating vacuumsexceeding 29 in-Hg. The feed port 126 was vented to atmosphericpressure, and therefore the TMP was about 14.7 psi. The retentatepressure, or more precisely, the TCP, was finely regulated by means ofthe gravity siphon 240, whereby the height of the column of water 242essentially determines the TCP, the TCP being directly proportional tothe height of the column of water 242 (i.e., 26″ of water≈1 psi). Byadjusting the location of the reservoirs forming the gravity siphon 240the TCP is controlled within ±0.02 psi.

Example 3

In example 3 an SPF module with 600 μm hollow fiber membranes in a3-volume device similar to the sample preparation module 192 of FIG. 5Bwas used with vacuum sources to drive the single-pass ultrafiltration.This example illustrates the concentration of 10 mg/ml BSA using 10,000MWCO hollow fibers with lumen diameter of about 600 μm and 155 cm long.The module 192 comprised a separation element 194 having a single hollowfiber membrane with an area of about 29 cm². The feed stream comprisedof about 5.2 ml of BSA solution; the TCP was about 33 in-H₂O, or 1.3psi; a buffer chase of about 0.1 ml, introduced as described in step 324of FIG. 8, was used to displace the residual liquid; and the retentatewas recovered in the retentate reservoir.

It took about 5.9 minutes to complete the ultrafiltration, producingabout 0.427 g of retentate (including the buffer chase), resulting in aconversion of about 92% and an average flux of about 17 lmh. The BSArecovery in the retentate was 98%. The hollow fiber module had aspecific membrane area of the channel, _(C), of about 67 cm⁻¹ and adimensionless length, of about 10,300. The process was operated at aspecific membrane area of the sample, _(M), of 5.9 cm⁻¹. The SPF processutilizing vacuum sources performed similarly to the SPF processutilizing pressure sources. No complications were observed, for exampleout-gassing, resulting from the use of a deep vacuum in the permeatevolume.

The following description illustrates results from simulations that usevarious principles of the present teachings and invention. Thesesimulations are not exhaustive and are not intended to limit the scopeof the present invention. Simulations 1 through 4 were calculatedpredictions based on a one-dimensional, steady-state mathematical modelfor the ultrafiltration of protein solutions utilizing hollow fibermembranes. The model takes into account the following factors:

1. the osmotic pressure of the protein solution as a function ofconcentration;

2. the hydraulic permeability of the membrane;

3. the dimensions of the hollow fiber;

4. concentration polarization resulting from the interplay of permeationand radial diffusion of solute transport in circular tubes under laminarflow;

5. the pressure drop along the flow channel; and

6. the increase in solute concentration along the flow channel as aresult of permeation.

Numerical integration of the differential equations was performed usingMathCAD version 12. Physical properties of BSA found in the technicalliterature (osmotic pressure, viscosity and diffusion coefficient) wereused to perform each simulation. Multiple simulations were done usingvarious conditions of pressures, feed concentration, membranepermeability, hollow fiber dimensions and conversions to illustrate thevarious aspects of the invention.

Simulation 1

Simulation 1 was performed for a 3-volume device with a hollow fiber(HF) separation element consisting of 10 flow channels with a lumendiameter of 0.02 cm and a length of 100 cm. The device has a feedreservoir with a 4 cc feed volume and is loaded with a feed sample ofabout 3 cc. The membrane area of the separation element is about 63square centimeters, resulting in a value of _(M) for the method of about21 cm⁻¹, a value of ₁ and _(C) for the device of about 16 and 200 cm⁻¹,respectively, and a _(C)-to-₁ ratio for the device of about 13. Thesimulation results in the following prediction: a single-pass conversionof about 90% can be achieved in a period of about 2 minutes.

Simulation 2

Simulation 2 was performed, similar to simulation 1 except that thedevice had only one flow channel, a feed reservoir with a 1 cc feedvolume, and is loaded with a feed sample of about 0.3 cc. The membranearea of the separation element is about 6.3 square centimeters,resulting in a value of _(M) for the method of about 21 cm⁻¹, a value of₁ and _(C) for the device of about 6 and 200 cm⁻¹, respectively, and a_(C)-to-₁ ratio for the device of about 33. The simulation results inthe following prediction: a single-pass conversion of about 90% can beachieved in a period of about 2 minutes. Additional simulations 2A and2B illustrating the use of the quantitative parameter in equation 7 wereperformed for a 3-volume device with a HF separation element consistingof 10 flow channels with a lumen diameter of 0.04 cm and a length, L, of100 cm. The device has a feed reservoir with a 4 cc feed volume and isloaded with a feed sample of about 3 cc. The membrane area of theseparation element is about 126 square centimeters, resulting in a valueof _(M) for the method of about 42 cm⁻¹, and a value of ₁ and _(C) forthe device of about 32 and 100 cm⁻¹, respectively. The value of is about15,400. The simulation results in the following prediction: with a TCPof about 0.03 Bar a single-pass conversion of about 90% can be achievedin a period of about 2 minutes. A second simulation was performed on a3-volume device with a HF separation element consisting of one flowchannel with a lumen diameter of 0.02 cm and a length, L, of 100 cm. Thedevice has a feed reservoir with a 1 cc feed volume and is loaded with afeed sample of about 0.3 cc. The membrane area of the separation elementis about 6.3 square centimeters, resulting in a value of _(M) for themethod of about 21 cm⁻¹, and a value of ₁ and _(C) for the device ofabout 6.3 and 200 cm⁻¹, respectively. The value of is about 30,900. Thesimulation results in the following prediction: with a TCP of about 0.2Bar a single-pass conversion of about 90% can be achieved in a period ofabout 2 minutes.

Simulation 3

A simulation was performed for a 3-volume device in a centrifugal fieldwith an acceleration of about 2,000 g using a HF separation elementconsisting of 2 flow channels with a lumen diameter of 0.02 cm and alength of 100 cm. The device has a feed reservoir with a 4 cc feedvolume and is loaded with a feed sample of about 3 cc. The separationelement is located about 1.02 cm below the feed sample reservoir and theretentate reservoir is located about 0.73 cm below the feed samplereservoir. The membrane area of the separation element is about 6.3square centimeters, resulting in a value of _(M) for the method of about2 cm⁻¹, and a value of ₁ and _(C) for the device of about 1.6 and 200cm⁻¹, respectively. The simulation results in the following prediction:the TCP is about 0.03 bar, and a single-pass conversion of about 95% canbe achieved in a period of about 13 minutes.

Simulation 4

A simulation was performed for a 3-volume device comprising a feedreservoir with a feed volume of about 4 cc and a HF separation elementconsisting of 10 flow channels with a lumen diameter of 0.03 cm and alength of 150 cm. The feed reservoir is loaded with about 3 cc of a feedsample and is vented to atmospheric pressure, while the retentate andpermeate reservoirs are connected to vacuum sources at about 0.9 and0.05 bar-absolute, respectively. On application of these pressures thefiltration process starts. When about 0.5 cc of sample is left in thefeed reservoir, the permeate reservoir is vented to atmospheric pressureand the vacuum source connected to the retentate reservoir is raised toabout 0.95 bar-absolute. The permeation process is thereby substantiallystopped while the remaining 0.5 cc of feed sample flows along the hollowfiber lumen by virtue of the TCP (at about 0.05 bar), thereby displacingthe residual liquid contained within the channel volume. The value of ₁and _(C) for this device are about 35 and 133 cm⁻¹, respectively, andthe value of _(M) for the method is about 47 cm⁻¹. The simulationresults in the following prediction: a single-pass conversion of about90% is achieved in a period of about 1.5 minutes with over 90% recoveryof the retained species.

Now turning to FIG. 11A, a sample preparation system 390 includes a2-volume sample preparation module 400 comprising a housing 402, aseparation element 404 disposed within the housing 402 comprising apermeate compartment 430 and at least one flow channel 406 having aninlet 410, an outlet 412 and a surface comprising a filtration membrane408. The 2-volume module 400 is useful when the desired result ofprocessing a sample is the permeate fraction. The module 400 furthercomprises a feed reservoir 414 fluidly coupled to the channel inlet 410through a feed flow passage 420, a hydrophobic vent 412 affixed to thechannel 406 distally from the inlet 410 and a permeate reservoir 418fluidly coupled to the separation element 404 through a permeate flowpassage 424. In one embodiment the hydrophobic vent 412 is disposed atthe end of the channel 406, and in another embodiment the hydrophobicvent 412 forms a portion of the flow channel 406. The system 390 furtherincludes a feed pressure source 432 coupled to the module 400. Themodule 400 additionally comprises a feed port 426 coupled to the feedreservoir 414 coupled to the feed pressure source 432, and a permeateport 436 coupled to the permeate reservoir 418. It will be appreciatedthat the position of the hydrophobic vent 412 can vary at the distal endof the channel 406, for example the vent 412 can be located along thewalls of the channel 406 instead of the end of the channel 406.

In operation, the feed port 426 is used to introduce the feed sampleinto the feed reservoir 414 and then to connect the feed pressure source432 to the feed reservoir 414. The feed pressure is set to a pressure toprovide a positive pressure differential between the feed port 426 andthe permeate port 436. Here, the permeate reservoir 418 is vented to theatmosphere. The pressure differential provides the necessary drivingforces for tangential flow by inducing the TCP and for permeation byinducing the TMP. Timed application of this pressure differentialcontrols the conversion of the liquid sample volume in the feedreservoir 414 into the permeate volume in the permeate reservoir 418.When the sample processing is completed, the permeate can be withdrawnthrough the permeate port 436. Other methods of recovering the samplefractions are described below in conjunction with FIG. 15. The pressuredifferential is provided by a pressure source, vacuum source, or by theapplication of centrifugal acceleration. It is noted that 2-volumemodules need only one pressure or one vacuum source, said source beingutilized to create the TMP, thereby inducing the permeation through themembrane. The second pressure differential, the TCP, is created by thetangential flow induced in the flow channel by the permeation, and istherefore, not directly controlled.

A practical consideration in the sample-preparation devices of thepresent invention is that it may be desirable to have the volume of thefeed container be greater than the interior volume of the flow channel.This practical consideration implies that the ratio of _(C) to ₁ shouldbe greater than about 1.0, preferably greater than about 3.0, and morepreferably greater than about 10. In various embodiments, it may beconvenient for the TCP to be greater than about 0.02 psi, e.g. tofacilitate control of the TCP. In various embodiments, it has beendiscovered that this goal can be realized if the device design andmethod meets the following relationship: α>10,000.

Now referring to FIG. 11B, in which like elements are provided havinglike reference designations as in FIG. 11A, a sample preparation system390′ includes a 2-volume sample preparation module 400′ similar tomodule 400 of FIG. 11A and a pressure source 438 coupled to the permeatereservoir 418 via the permeate port 436. In addition, the feed reservoir414 is vented to the atmosphere instead of being coupled to pressuresource 432. In one embodiment, pressure source 438 is a vacuum pumpwhich provides a positive pressure differential between the feed port426 and the permeate port 436. In an alternative embodiment of modules400 and 400′, it is advantageous to utilize both pressure and vacuumsources connected to the feed reservoir 414 and permeate reservoir 418.In one embodiment, sample preparation system 390′ can process a samplein less than about 10 minutes and generate conversions exceeding about90% with retentate pressures between about 0.5 and about 0.98 Barabsolute; permeate pressures typically about 0.1 Bar absolute; resultingin a TMP of about 0.9 Bar and a TCP of about 0.02 to about 0.5 Bar.

While it is possible to operate the 2-volume modules 400 and 400′without a hydrophobic vent 412, the use of the hydrophobic vent 412facilitates the operation of 2-volume modules by venting of gasespresent within the flow channel at the start of permeation andfacilitating the recovery of residual permeate or retentate at the endof permeation, which can be accomplished, for example, by inducing a(positive) pressure differential between the permeate and the feedreservoirs. In some embodiments, the hydrophobic vent provides theseoperational benefits by fluidly connecting the interior of the flowchannel to the permeate reservoir.

Now referring to FIG. 12, in which like elements are provided havinglike reference designations as in FIG. 11A, a sample preparation system390″ includes a 2-volume sample preparation module 400″ similar tomodule 400 of FIG. 11A. Here, system 390″ does not include any directlycoupled pressure sources. The feed reservoir 414, and permeate reservoir418 are vented to the atmosphere instead of being coupled to pressuresources. Here, the driving forces are provided by a centrifuge (notshown) with a centrifugal acceleration vector indicated by arrow 440.The feed reservoir 414 and the permeate reservoir 118 are juxtaposedalong the centrifugal acceleration vector 440, the feed reservoir 414and the permeate reservoir 418 at opposite ends of the centrifugalacceleration vector 440. In one embodiment, the specific membrane areaof the flow channel 406 is greater than about 80 cm⁻¹ and the specificmembrane area of the module, ₁, is greater than about 2-cm⁻¹.

In operation, the centrifuge provides the pressure differential drivingforces. The location and orientation of the feed reservoir 414, thepermeate reservoir 418 and the separation element 404 with respect tothe centrifugal acceleration vector 440 determine the TCP and TMP. Invarious embodiments, the relative location of the separation element 404provides the ability to control induced TCP substantially independentlyof the induced TMP by locating the hydrophobic vent 412 relative to theaverage location of the membrane in the separation element 404. Theports 426 and 436, and flow passages 420 and 424 provide for adding andremoving liquids as well as venting to the atmosphere and the locationof these ports and passages as shown in FIG. 12 is not intended to limitthe invention in any way. Vacuum and other pressure sources could beoptionally used for recovery if desired.

In certain embodiments of the sample-preparation modules utilizing acentrifugal driving force, as exemplified in FIGS. 2 and 12, adifference in the position of the feed and retentate reservoirs, e.g.,of about 2 to 4 mm with respect to the direction of the accelerationvector can induce the TCP necessary to create tangential flow. A largerdifference in the position between the feed and the permeate volume,e.g., of about 1 centimeter being adequate to induce the TMP necessaryto create permeation if the centrifugal acceleration is about 1,000 g.

Referring to FIG. 13 a 2-volume sample preparation module 460 similar tomodule 400 of FIG. 11A includes a permeate reservoir 470, a permeateport 482 fluidly coupled to the permeate reservoir 470, and a separationelement 478 which is integrated within the permeate reservoir 470. Theseparation element 478 includes flow channel 464 and membrane 468. Themodule 460 further includes a feed reservoir 474, a feed passage 466fluidly coupled to the flow channel 464 and the feed reservoir 474, anda feed port 476 fluidly coupled to the feed reservoir 474. In operation,a sample is supplied through feed port 476 and a positive pressuresource (not shown) is connected to the feed reservoir 474 through feedport 476 to drive permeation. Alternatively, a vacuum source isconnected to the permeate reservoir 470 through port 482 to drivepermeation. The permeate port 482 is used recover the permeate.

In alternative 2-volume embodiments, it is possible for the feed streamto flow on the outside of hollow fiber membranes with the permeateentering the lumen of the hollow fiber membranes and flowing on theinside of the membrane. Referring to FIG. 14, a 2-volume module 480includes a feed reservoir 482, a permeate reservoir 496, a feed port 490fluidly coupled to the feed reservoir 482, a permeate port 492 fluidlycoupled to the permeate reservoir 496, a permeate passage 498 fluidlycoupled to the permeate reservoir 496 and a separation element 486disposed within the feed reservoir 482. The separation element 486includes a flow channel 484 having a membrane surface 488 and coupled tothe permeate passage 498.

In operation, a sample is supplied through feed port 490 and a positivepressure source (not shown) is connected to the feed reservoir 482through feed port 490 to drive permeation. Alternatively, a vacuumsource is connected to the permeate reservoir 496 through port 492 todrive permeation. Here, the flow channel 484 carries permeate ratherthan retentate and the interior of the flow channel 484 is in fluidcommunication with the permeate reservoir. In alternative embodiments,the feed port 490 and the permeate port 492 are used to apply thepressure differential, and the permeate port 492 is used remove thepermeate.

Turning now to FIG. 15, a flow diagram illustrates a process forprocessing a sample and recovering the permeate fraction using 2-Volumedevices. The systems 400 and 400′ of FIGS. 11A and 11B, respectively,are used in explaining the exemplary methods. The process commences instep 500, following which a predetermined volume of sample is suppliedinto the feed reservoir 414 at step 502. In step 504 the feed reservoir414 is connected a pressure source 432 (or alternatively permeatereservoir 418 is connected to pressure source 438). It is understoodthat either positive pressure sources, for example, pumps or pressurizedgas can be used or alternatively negative pressure vacuum sources can beused as well as centrifugal forces. Venting through hydrophobic vent 412occurs at the start of the SPF process to allow displacement of the airpresent within the flow channel. In step 506, the pressure differentialis applied inducing a positive and controllable TMP. Processing of thesample continues in step 508 until the sample is substantially consumed.In step 510, the pressure differential is dissipated by disconnecting orshutting off the pressure source. If a displacement method is being usedto recover the retentate, processing continues in step 512 otherwise thepermeate fraction is directly withdrawn from the permeate reservoir 418in step 522 by means of a manual or automatic syringe or pipette, oralternatively by pouring the contents of the reservoir into anothercontainer, and the process is finished in step 524.

In another method suitable for 2-volume devices, the residual liquid andsmall amount of permeate are displaced towards the feed reservoir andthen collected from the feed reservoir starting at step 512. In step512, a portion of the permeate is utilized as the displacement medium byinducing reverse permeation by applying a small negative TMP after thefeed sample is substantially consumed. The negative TMP causes a smallamount of permeate to flow into the interior of the flow channel therebydisplacing the residual fluid within the flow channel 106 by reversepermeation. The residual liquid, together with the small amount ofpermeate used as the displacement medium) is collected in the feedreservoir 414 and withdrawn in step 516 and the process is finished instep 524. In still another variant to this latter displacement method,suitable for 2-volume devices equipped with a hydrophobic vent 412,pressurized gas in the permeate compartment is utilized to displace theresidual liquid back to the feed reservoir 414; the gas displacementmedium originating from the permeate reservoir 418 used instead of aliquid.

The invention will be further described in the following example, whichis not exhaustive and does not limit the scope of the inventiondescribed in the claims.

Example 4

In example 4 an SPF module with a 600 μm hollow fiber membranes in a2-volume device similar to the sample preparation module 400′ of FIG.11B was used with vacuum sources to drive the SPF ultrafiltrationprocess. This example utilized the same module used in Example 3 with asimulated hydrophobic vent. To simulate the presence of a hydrophobicvent at the distal end of the hollow fiber, an additional “venting” stepwas added to the test procedure. The venting step comprised filling upof the flow channel with a small amount of the sample prior to the startof permeation (i.e., prior to the application of a full vacuum to thepermeate reservoir). This was accomplished by first applying the vacuumfrom the gravity siphon (about 33 in-H₂O, or 1.3 psi) to the retentatereservoir, which aspirated the sample into the flow channel until liquidshowed up in the retentate reservoir, at which point the retentate pinchvalve 238, located immediately downstream of the module, was shut off.In this manner any gas present within the flow channel is displacedprior to the start of permeation. In the event that the module possesseda hydrophobic vent, the venting would occur automatically without theneed for this venting step.

The 2-volume SPF module comprised a separation element made with asingle hollow fiber membrane with a lumen diameter of about 600 μm, alength of about 155 cm and an area of about 29 cm². The feed streamcomprised of about 5.24 ml of BSA solution, and permeation proceededuntil the feed sample was substantially consumed. The retentate wasrecovered in the feed reservoir by a process similar to step 512 of FIG.15, as follows: apply a small vacuum of about 1.3 psi (utilizing thegravity siphon as the vacuum source) to the feed reservoir whilesimultaneously opening the retentate pinch valve to simulate the actionof a hydrophobic vent.

The ultrafiltration process took about 7.2 minutes to complete,producing about 0.65 g of retentate, resulting in a conversion of about88% and an average flux of about 13 lmh. The BSA recovery in theretentate was 86%. Since the volume of the flow channel is about 0.44ml, it is estimated that about 0.2 ml of liquid permeated back throughthe membrane (i.e., permeate present in the permeate reservoir) duringthe dwell time between the end of permeation and the recovery of thepermeate. This “reverse permeation” is believed to have been induced bythe osmotic pressure of the residual liquid within the flow channel. Thehollow fiber module had a specific membrane area of the channel, _(C),of about 67 cm⁻¹ and a dimensionless length, of about 10,300. Theprocess was operated at a specific membrane area of the sample, _(M), of5.5 cm⁻¹. As expected, the flux of the 2-volume device is about 25%lower than that of a 3-volume device with the same separation elementdue to the fact that the retentate is accumulated within the flowchannel.

Referring to FIG. 16, a 2-volume separation module 540, suitable forvery low volume samples (less than 50 μL) where pressure differentialsare induced by capillary forces, comprises separation element 542 havinga thick-walled hollow fiber membrane 552. The lumen of the hollow fibermembrane 552 forms flow channel 554 and in one embodiment has a diameter570 of about 100 micrometers and a length 572 of about 6 centimeters.The hollow fiber membrane 552 comprises a hollow fiber wall 556 and anultrafiltration membrane 558 on the lumen inside diameter supported bythe hollow fiber wall 556. The module 540 has a proximal end 560, adistal end 562, and an outside diameter 574, in one embodiment about 350micrometers. The module 540 further comprises seal 544 and an end cap546 forming an upper port and end caps 548 forming a lower port. In oneembodiment the module 540 has a membrane area of about 0.2 cm² and thehollow fiber wall 556 has a porosity ε between about 0.6 and 0.8.

In operation, the proximal end 560 of module 540 is dipped into samplereservoir (not shown), and the suction created by the capillary actionproduced by the lumen draws the sample into the flow channel 554creating a tangential flow. The suction created by the capillarity ofthe porous structure of the wall 556 causes a portion of the liquidsample to permeate through the ultrafiltration membrane 458. In oneembodiment, the void volume of the hollow fiber wall 556 is about 4.5microliters, and the void volume of the flow channel 554 is about 0.5microliters, resulting in an about 90% conversion of a 5 microliter feedsample. At the end of the ultrafiltration process the retentate occupiesthe hollow fiber lumen 552, which can be removed by various methods, forexample, by suction with a micro-bore syringe, or by a small centrifugalaction. In some applications, a small portion of the retentate is drawninto a subsequent analytical device, for example, a capillaryelectrophoresis column. In these applications, the tip of the capillaryelectrophoresis column is inserted into the hollow fiber lumen 552 atthe distal end 562, followed by the application of a suitableelectromotive force to load the solutes present in the retentate intothe capillary electrophoresis column. In these embodiments, _(M) isabout 40 cm⁻¹, _(c) is about 200 cm⁻¹ and is about 200. An array ofmodules 540 can also be used in an automated sample processing systemsusing sample handling techniques known in the art. In alternativeembodiments, the separation element can comprise flat-sheet membranes,microfiltration membranes or membrane monoliths.

In alternative embodiments, the inventive modules can also be used toperform a diafiltration process. In diafiltration, a buffer solutionreplaces the solution that permeates through the membrane in order tochange the composition of the solution in which the retained solutes aredissolved. The addition of the replacement solution can be performed,for example, substantially simultaneously with permeation, sequentiallyalternating between permeation and dilution steps, or in a combinationof steps.

Now referring to FIG. 17, a vacuum controlled device 600 (also referredto as VacuCon 600) includes a feed port 601 for attaching a feedreservoir 602 (also referred to as a sample reservoir 602), a retentateport 603 for attaching an optional retentate reservoir 604, both coupledto a filter 606 (also referred to as SPF filter 606) in a housing 608.The SPF filter 606 includes a single pass TFF separation element 610(also referred to as separation element 610). The single pass TFFseparation element 610 comprises a membrane (not shown), the filter 606is disposed within the housing 608 and includes at least one flowchannel having a flow channel inlet disposed at a first end of the flowchannel and coupled to the feed port 601, a flow channel outlet coupledto the retentate port 603 and disposed at a second opposite end of theseparation element 610. The housing 608 has a permeate port 612 adaptedto be coupled with a vacuum box 630 which includes a permeate reservoir614. In one embodiment the VacuCon 600 is connected to the vacuum box630 which in one embodiment is a solid phase extraction (SPE) vacuumbox.

As described above, the single pass TFF separation element 610 has atleast one flow channel with characteristics which enable the single passoperation of device 600. In one embodiment, these characteristicsinclude a specific membrane area of the at least one channel is greaterthan about 40 cm⁻¹ and the flow channel has a length a characterized bya dimensionless length greater than about 4000.

As shown in FIG. 18 in further detail, the VacuCon 600 housing 608 ofFIG. 17 is sealed with a cap 628 which includes the feed port 601 andthe retentate port 603. The SPF filter 606 further includes a reusablecore 620, for example a machined part made of nylon. The core 620 iscoupled to the cap 628 forming the feed port 601 which in one embodimentis an inlet luer connector to which the feed reservoir 602 engages. TheSPF filter 606 includes in one embodiment, a hollow-fiber separationelement 610, comprising a hollow fiber membrane with elastomericconnectors potted and/or glued to both ends. In one embodiment, thehousing 608 is in the form of a syringe body that is adaptable toconnect to an SPE vacuum box and the feed port 601 and retentate port603 are included in the housing 608 which is sealable, for example, byusing an o-ring 629 disposed on the cap 628. Here, the sample reservoir602 is in one embodiment a syringe body or an empty SPE tube.

Referring again to FIG. 18, the core 620 is connected by means of alongitudinal concentric bore to a connector at the bottom end of thecore. The inlet of the separation element 610 is attached to this bottomconnector, while the outlet is attached to the other connector thatdirects the retained fraction (the “retentate”) to the side port of thecore 620. In this manner the VacuCon 600 enables the collection of theretained fraction from the side retentate port 603. The design of theVacuCon 600 provides flexibility since different separation elementshaving different hollow fiber membranes and different lengths can beeasily configured and assembled into the finished device using existingcomponents and the reusable core 620 and cap 628. In one embodiment, theseparation element comprises a single 0.50 mm ID×135 cm long hollowfiber membrane. In this embodiment, polysulfone hollow fibers of 30,000MWCO (molecular weight cut off) from GEHealthCare (Westborough, Mass.)are used.

In one embodiment, as shown in FIG. 19, the assembled VacuCon 600 ismounted on vacuum box 630, which is attached to a vacuum pump (notshown) through controllable vacuum port 633, and the desired sampleintroduced into the sample reservoir 602. The set-up further comprisesan optional permeate valve 624, an optional feed valve 623 and anoptional retentate valve 622, which are optionally used to control thepermeation process. The permeate and retentate fractions are collectedrespectively in the permeate reservoir 614 and retentate reservoir 604.The retentate reservoir 604 can be connected to a second controlledvacuum source, as shown in FIG. 19, which in this embodiment is derivedfrom the vacuum pump and coupled to the vacuum box 630. To start thepermeation process, both vacuum sources are turned on simultaneously;the sample is drawn into separation element 610 by the retentate vacuum634, while permeation is induced by the main vacuum. In one embodiment,the retentate vacuum is adjusted by vacuum adjustment 636, which in oneembodiment comprises a controlled air bleed by means of a tee 638, afirst section of tubing 640 connected to the primary vacuum source 632,and a second section of tubing 642 whose the length and diameter arevaried such that the higher the hydraulic resistance of the tubing 642the higher the retentate vacuum It is understood, that the pressuredifferentials created by the vacuum pump through the vacuum box 630 canbe replaced with a positive pressure source, for example, a pump or apressurized gas source to supply the feed directly to the feed port 601and a second pump or second pressurized gas source to control theretentate flow, or alternatively, by combinations ofpumps/pressure/vacuum sources.

The vacuum controlled SPF filter 606 is highly versatile since it can beused both as a 2-volume and 3-volume device as described above. Thisenables VacuCon 600 to be tailored to a variety of applications. In“2-volume mode” the retentate accumulates within the void volume of theseparation element (i.e., no retentate is collected in the retentatereservoir 604 during permeation.

In operation, the air within the separation element 610 is displaced byopening of the 3-way the permeate valve 624. The pressure differentialbetween the feed and permeate reservoir (the “trans-membrane pressure”or “TMP”), created by the vacuum 632 in the permeate reservoir, drivesthe permeation. This process continues until the sample is consumed, atwhich point the permeate valve is closed and the vacuum released to stoppermeation. This mode is particularly suitable in applications in whichthe fraction of interest is the permeate and the final concentration ofthe retentate is not very high. However, one may still recover theretentate fraction accumulated within the void volume of the separationelement by opening the retentate valve 622 and “sucking out” the voidvolume of the hollow fiber using one of the several recovery methodsdescribed above (e.g. simple displacement, or reverse permeation, orcombinations thereof).

In 3-volume operation, the retentate is slowly and continuouslywithdrawn simultaneously with permeation establishing a steady-state orquasi steady-state process. To start permeation, both the permeate valve624 and retentate valve 622 are simultaneously opened, the retentatevacuum 634 determining relative flow rate of retentate and permeatethereby determining the concentration factor of the retentate fraction.This process continues until the sample is fully consumed and bothfractions collected in their respective reservoirs. This mode requires asecond controlled vacuum source 634 for the retentate, and isparticularly suitable for applications in which the concentration of theretained species in the feed sample is very high (e.g. when processingplasma, serum or even whole blood).

In another embodiment the VacuCon 600 separation element 610 includesone hollow fiber membrane, 120 cm in length and a membrane area of about20 cm². In another embodiment, the VacuCon 600 includes two hollow fibermembranes in parallel, each 60 cm also with a membrane area of about 20cm². In the experiments described below, the permeate vacuum was 27in-Hg and the retentate vacuum level was adjusted to control the flowrate along the fiber lumen. The predicted values of permeate recoverywere obtained using a single pass filter simulator. In still otherembodiments more than two hollow fiber membranes, all of equal lengths,are used to provide the separation element 610.

Graph 700 in FIG. 20 summarizes the comparison between predicted andmeasured permeate recoveries for processing 5 ml volumes of BSA solution(the permeate recovery being defined as the weight of permeate dividedby the weight of feed solution). As can be seen, the agreement betweenpredicted and measured values is excellent over an approximate 70× rangeof BSA concentrations (0.05˜3.5%), and confirms the predictability andperformance of the mathematical model.

Graph 720 in FIG. 21 shows the recovery of permeate as a function oftime for one-fiber devices (120 cm long) and two-fiber devices (2×60 cmlong) for three BSA concentration levels and, as expected, recoveryrates were very similar. As predicted, the recoveries of permeate aremore rapid at low protein concentration, but even at 3.5% BSA a recoveryof more than 70% can be attained in about 10 minutes.

Graph 740 in FIG. 22 shows a performance comparison between the vacuumcontrolled device 600 and a conventional Amicon Ultra-4 centrifugaldevice, an existing ultrafiltration (UF) device used to concentrateproteins in life science laboratories. The time to filter 5 ml of 3.5%BSA using the Amicon centrifugal device was compared with that obtainedwith the VacuCon 600 hollow fiber device. As can be seen, the vacuumcontrolled device 600 processes the sample about four times faster thanthe Amicon centrifugal device even though the VacuCon 600 is driven onlyby a vacuum which is effectively at only 14.1 psig below atmosphericpressure. This large reduction in processing time is due to the largermembrane area of the VacuCon 600 device and its dramatically higherefficiency due to effective control of the boundary layer resistance.

An important goal in concentration of proteins by ultrafiltration is toachieve a high recovery of the protein in the retentate. A comparison ofthe recovery of protein in the retentate with vacuum controlled device600 devices vs. centrifugal devices is shown in Table 6 for 10-foldconcentration of the feed solution. Within the limits of the analyticalmethod optical density at 280 nanometers, the recoveries of both typesof devices are substantially equivalent quantitative recoveries.

TABLE 6 Protein Recovery of VacuCon vs. Amicon Centrifugal Device. FeedSample Protein Recovery Conc. VacuCon Amicon Ultra-15 [w/w %] HF DeviceCentrif Device 0.05% 97% 93% 1.00% 95%Another set of experiments were run to demonstrate that low molecularweight solutes such as NaCl will permeate freely while a protein (BSA)is retained. A comparison of NaCl permeation with the VacuCon 600 vs.centrifugal devices (Amicon Ultra-15) was conducted with a feed solutionof 0.05% BSA in phosphate-buffered-saline (PBS) buffer and 1N NaCl.

The results are summarized in Table 7 and demonstrate that both devicesare virtually identical in the desalting of protein solutions. Bothdevices enable NaCl to permeate freely as evidenced by the fact that theNaCl concentration of the permeate fraction is equal to that of the feedsample, whereas the protein was concentrated 20-fold. It should be notedas shown in Table 7, that the protein concentration used in theseexperiments was kept quite low in order to obtain reasonable processingtimes for the centrifugal device.

TABLE 7 NaCl Removal from Protein Solutions. NaCl Concentration BSAConcentration Device In Feed In Permeate In Retentate In PermeateCentrifugal 6.01% 6.09% 1.43% 0.05% Centrifugal 6.01% 6.09% 1.14% 0.05%VacuCon HF 6.45% 6.55% 1.38% 0.05% VacuCon HF 6.45% 6.45% 0.95% 0.05%

Experiments with high BSA concentration as reported above demonstratethat high recovery of the target protein can be obtained when the feedsolution is at a high concentration (1-3%). To demonstrate high recoveryat low concentration a series of experiments were done using human IgGat increasingly lower concentrations. These experiments demonstrated theperformance of a VacuCon 600 comprising a single 120 cm hollow fiber (20cm² of membrane area) and a 6 ml sample of IgG in PBS.

A sequence of 3 experiments were done, each one with the IgG samplediluted by 10×, starting at 0.05% (500 μg/ml), then 0.005% (50 μg/ml)and 0.0005% (5 μg/ml). As shown in Table 8, quantitative recovery wasobtained within the limits of detection of our test method,demonstrating the capability of the VacuCon 600 in recovering theretentate fraction, and further demonstrating that binding losses didnot contribute to significant losses even at these low proteinconcentrations. The whole procedure, including the recovery of theretentate fraction (contained in the hollow fiber lumen), took less than5 min.

TABLE 8 IgG Recovery at Low Concentrations. Run Run Run Run #1 #2 #3 #4IgG Conc. [μg/ml] 5 50 50 50 Sample Volume [ml] 6.227 6.221 6.101 6.187Specific Mass Load [μg/cm²] 1.6 16.0 15.6 15.9 Mass Balance Fraction ofIgG in Feed 100% 100% 100% 100% Retentate 102%  82%  87%  88% Chase  18% 1%  3%  3% Fractional Mass Loss −21%  17%  10%  10% Test Conditions 25in-Hg vacuum; 2-Volume Operation; 10× Concentration Factor; 2½ minutesof Permeation, followed by 2 minute dwell;

In a clinical setting, one example of this type of applications isassays for the determination of free-drug and free-hormones in plasma.To measure the free-analyte, one has to remove the high abundanceproteins and the analyte bound to large proteins. Since these proteinsare relatively large, a UF membrane is capable of selectively removingthem while enabling the permeation of the free, unbound component.

A second type of these applications is a set of assays for thedetermination of analytes at very low concentration, hereafter referredto as biomarkers. These biomarkers are present at very lowconcentrations, anywhere from a thousandth to a billionth of theconcentration of albumin in native plasma. To suppress interferences andachieve the required resolution, abundant species need to be removed. Inthis application a UF membrane can selectively remove the large proteinswhile enabling the permeation of the biomarker.

The performance of the VacuCon 600 was tested for abundant proteinremoval, utilizing two low molecular weight species as suitable modelsfor biomarkers: fluorescein (“F”) and fluorescein-tagged-angiotensin-II(“AGF”). The benefit of using these fluorescent markers is that they areeasy to detect and quantify in binary systems. BSA was included in thesamples for the following experiments at concentrations that modelabundant proteins in plasma and, in effect, the BSA was used as a modelcompound to mimic plasma itself.

The initial experiments demonstrated that both F and AGF were mostlybound to both BSA and to the membrane itself. Binding to the membranewas not surprising since the polysulfone hollow fiber membrane used inthese experiments is hydrophobic and that characteristic of the membranematerial leads to interaction with hydrophobic portions of both F andAGF. Accordingly, an effective method for the determination of lowabundance biomarkers needs to either suppress the binding of thebiomarker to the membrane or, alternatively, elute the biomarker boundfrom the membrane post-fractionation.

Several methods are used to handle protein and membrane binding issues,as follows:

-   1. Use of a chaotropic agent (e.g. 8 Molar Guanidine HCl) to disrupt    intermolecular binding in the feed sample and to suppress all    non-specific binding including to the membrane;-   2. Eluting the membrane-bound sample with an organic solvent (e.g.    20% acetonitrile) immediately after the fractionation of the sample;    and-   3. treating the membrane with a surfactant prior to the assay.-   Another approach to preventing non-specific binding to the membrane    is to use a membrane made of a different polymer (e.g., regenerated    cellulose).    Experiments with 8 Molar Guanidine HCl to Suppress Binding and AGF    as Biomarker

The main advantage of this approach is that chaotropic reagents such asguanidine-HCl not only suppress binding to the membrane but also disruptthe binding of the analyte to proteins and thus eliminate theconfounding effects of protein-protein or protein-analyte binding. Thesemethods, therefore, are only capable of measuring total analyte vs. freeanalyte.

A series of experiments were run using 8 Molar Guanidine HCl, 150 mMolarTris buffer and 5 v/v % n-propanol (“Reagent A”). To simulate biomarkersin plasma, 3% BSA in PBS buffer was spiked with AGF at a concentration a0.5 ppm (the “plasma model” sample). Reagent A was then mixed with the“plasma model” sample at a 4:1 ratio, which was then used as the feedsample for fractionation with the VacuCon 600. To detect AGF in thepermeate fraction, a fluorometer was used to analyze and compare thefeed and permeate samples. In all cases the fluorometer was calibratedto read 500 Fluorescent Units (“FU”) full-scale for the feed sample.

Multiple tests were conducted with a VacuCon 600 having a single 130 cmhollow fiber (membrane area≈20 cm²). In all cases, 3 ml samples wereused, with the results shown in Table 9.

TABLE 9 Abundant Protein Removal with Reagent A. Reten- Process-Permeate Permeate Opera- Sample tate ing Fluore- OD @ Test ting SizeVacuum Time scence 280 nm # Mode [ml] [psi] [min] [FU] [AU] 1 2-volume 3— 17 365 0.502 2 2-volume 1 —  5 — — 3-volume 2 1.8 14 515 — 3 3-volume3 1.3 10 498 0.448

The fluorescence of the permeate fractions were all equal to that of thefeed sample, demonstrating the complete passage of AGF (Note: the loweramount of fluorescence in Test #1 is the result of dilution of the feedsample caused by the solvent in the pre-wet membrane). Furthermore, theoptical density at 280 nanometers (OD) of the permeate fraction isequivalent to≈0.05% BSA, which is less than 1/10th the OD of the feedsample demonstrating a more than 10-fold removal of the BSA. In summary,the abundant protein was reduced more than 10× in the permeate fractionwhile the biomarker concentration remained the same as the feed sampledemonstrating the feasibility of this method for the isolation ofbiomarkers. It should be noted that, as expected, permeation using the3-volume mode proceeded faster than that using the 2-volume mode.

Experiments Using Organic Solvent to Elute Analyte Bound to Membrane

Membrane-bound analytes were stripped from the VacuCon 600 filter usingacetonitrile/PBS as an elution solvent that was delivered through thedevice after processing of the feed sample. The advantage of thisapproach (vs. use of a chaotropic reagent as above) is that the nativesample is first delivered directly into the VacuCon 600 thereby notdisturbing the native feed sample conditions by mixing with otherreagents. These are preferred conditions for conducting assays for freedrugs and free-hormones that may be present in plasma, serum, or otherbodily fluids.

This method requires 3 steps, as follows:

-   1. A native biological fluid sample (e.g. plasma or serum) is    fractionated with the VacuCon 600 using the 2-volume or 3-volume    mode. The retained species are removed in the retentate port, while    the permeating species (all low molecular-weight solutes including    free-analyte) pass through the membrane and are either collected in    the permeate or bound to the membrane and membrane-support    structure.-   2. PBS buffer is added to the feed reservoir to displace any feed    sample remaining within the hollow fiber lumen. This step removes    any sample left in the device.-   3. An eluent solution containing an organic solvent miscible with    aqueous solutions, such as ethanol, methanol, acetonitrile, etc. is    added to the feed reservoir and filtered through the membrane and    collected in the permeate reservoir. This solution elutes the    membrane-bound analyte(s). The concentrations of organic solvent    required to obtain quantitative recovery of the membrane-bound    species is typically in the range of 10 to 30 v/v %.

The permeate from step 3 would then be suitable for routine assay by aclinical analyzer or LC/MS methods. Clearly, this method requires thatone keep track of the dilution of the eluted permeate by the elutionsolvent in order to determine the concentration of free-analyte presentin the feed sample. Table 10 shows the results of an experiment thatdemonstrates this method. In this experiment sequential aliquots ofvarious solutions are processed through the VacuCon 600, each aliquotbeing 3 ml and processed through the VacuCon 600 in 2-volume mode.Aliquots #1 and #2 are 2 identical samples of PBS buffer with thepermeate fraction showing a fluorescence essentially at the backgroundof the fluorometer (approximately 50 FUs); i.e. no presence of theanalyte (F). Aliquots #3 and #4 are two identical samples of the modelfeed solution, showing once more no presence of F in the permeate. Thiscontrasts to aliquot #5, the first aliquote of eluent solution, whichhas a high amount of F (753 FUs). Aliquot #6 has a slight amount of F(73 FUs, about 23 FUs above the background), demonstrating that thefirst eluent aliquot removed the bulk of the membrane-bound F. Finally,aliquot #7 is at background, showing that all the F has been removed.

TABLE 10 Passage of Fluorescein Sample Processing Permeate PermeateAliquot Size Time Fluorescence OD @ 280 # Sample [ml] [s] [FU] nm [AU] 1PBS Buffer 3 35 49 0.016 2 PBS Buffer 3 32 52 0.012 3 F Solution 3 42 460.009 4 F Solution 3 33 43 0.006 5 Eluent Soln. 3 51 753  0.054 6 EluentSoln. 3 58 73 0.077 7 Eluent Soln. 3 — 48 0.071 The conditions for theseexperiments were the following: Model analyte: fluorescein (“F”), FeedSolution: 100 ppb in PBS buffer; Eluent solution: 20:80 (v/v)acetonitrile:PBS.

The calculated amount of F recovered (data not shown) confirmedquantitative recovery of the fluorescein after elution with the EluentSolution (20% acetonitrile (ACN) in PBS buffer). These experimentsdemonstrate the feasibility of using an organic solvent elution torecover analytes even when they bind to the membrane material. TheVacuCon 600 can be used for the fractionation of whole blood which iscommonly the first step in preparing blood samples in clinicallaboratories namely to separate the plasma or serum from the largercellular components.

Whole blood fractionation tests were conducted with anti-coagulated calfand porcine blood using VacuCon 600 hollow fiber devices. Whole bloodfractionation performance of the single pass filtration TFF technologywas compared to existing technology (i.e., the Centrifree® centrifugaldevices manufactured by Millipore Corp., Billerica Mass.) which arecommonly used for filtration of plasma samples. In fact, there a lack ofcommercially available products used for the filtration of whole bloodsamples and, as such, these comparisons were made with the closestcommercially available devices. A summary of the test results in shownin Table 11 and Table 12.

After 10 minutes of centrifugation (at approximately 350 G's) of wholeblood with the Centrifree® device, the cells were observed to besedimented to the bottom of the sample reservoir and because thecellular materials had clogged the membrane and prevented anypermeation. As shown in Table 11 the centrifugal devices with wholeblood had essentially no permeate at all due to the clogged and failedfiltration membranes. In contrast, a three-volume VacuCon 600 with a30,000 MWCO membrane was effective in rapidly fractionating a wholeblood sample into a permeate fraction substantially devoid of abundantproteins. As demonstrated by the data in Table 12, the VacuCon 600 doesnot become clogged by the cellular materials because the tangential flowsweeps continuously sweeps the cellular material away from the boundarylayer in the hollow fiber membrane, leaving the membrane surface free topermeate the continuously moving feed sample of whole blood.

TABLE 11 Performance of Centrifree Device with Whole Blood. ProcessingPlasma Test Blood Time Recovery * # Type [min] [w/w %] 1 Calf 7 none 2Porcine 8 none 3 Porcine 20  0.12%

TABLE 12 Performance of VacuCon with Whole Blood. Reten- Process- PlasmaPermeate Hollow Fiber tate ing Re- OD @ Test Length/Area Blood VacuumTime covery * 280 nm # [cm]/[cm²] Type [psi] [min] [w/w %] [AU] 1 135cm/20 cm² Calf 1.8 9 31% 0.814^(†) 2 ″ Porcine 1.3 25 66% 0.839^(†) 3 ″Porcine 3.0 17 40% 0.665^(†) 4 270 cm/40 cm² Calf 14.0 8 45% — 5 ″Porcine 14.0 13 30% — * Plasma Recovery = Fraction of Plasma in BloodSample Recovered as Permeate ^(†)These values of the Permeate OD areapproximately 1/100^(th) the OD of whole plasma.Table 12 shows the result of a series of experiments with whole bloodfractionation in a VacuCon 600. Plasma recoveries between 30 and 45%were obtained with processing times lower than 15 minutes. Furthermore,the protein content of the permeate fraction, as evidenced by theoptical density at 280 nanometers of the permeate was about 1/100^(th)that of plasma obtained by commonly used centrifugation protocols. Theseresults demonstrate the feasibility of fractionating whole blood simplyand rapidly with a VacuCon 600 for the production of a permeate fractionsuitable for biomarker assays, something that is not possible withcentrifugal devices. Further, the results suggest that this technologymay be suitable for use with microfiltration (MF) membranes and routineblood collection and fractionation in advance of clinical or moleculardiagnostics. Thus, the VacuCon 600 is effective in fractionatingbiological samples without the need of centrifuges for applications inwhich both the retentate and permeate fractions are of interest.Accordingly, this type of filter based fractionation of whole blood isuseful, because it is difficult or not possible to do with conventionalfiltration technology.

Now referring to FIG. 23, a schematic of a device 800 similar inoperation to device 600 in FIG. 17 includes a single pass TFF (SPF)module 806, a feed compartment 802 and a permeate compartment 814. TheSPF module 806 includes a housing 808, a single pass TFF (SPF)separation element 810, a feed port 801, a retentate port 803, apermeate port 812 and a vacuum port 833. SPF module 806 has a feedpassageway 816 and a retentate passageway 818 (not shown) that connectinlet and outlet of SPF separation element 810 to feed and retentateports 801 and 803, respectively. SPF module 806 also has vacuumpassageways 835 connected to the vacuum port 833 at one end and thepermeate port 812 at a second end. In operation, SPF module 806 isdriven by vacuum source (not shown) connected to vacuum port 833.

In one embodiment the permeate compartment 814 can be removeablyconnected with the SPF module 806 via permeate port 812, enabling it tobe separated from the housing 808 to recover the permeate. In anotherembodiment the feed compartment 802 can be removeably connected with theSPF module 806 via feed port 801, enabling feed compartments ofdifferent sizes to be connected to the same SPF module 806. In anotherembodiment device 800 includes a retentate compartment (not shown)removeably connected to retentate port 803 and having a second vacuumport (not shown) connected to a second vacuum source (not shown). Insome embodiments the second vacuum source is derived from the mainvacuum source connected to vacuum port 833, in which case SPF module 806has a second vacuum port (not shown) removeably connected to theretentate compartment; in these embodiments the second vacuum source isgenerated internally within the SPF module 806 by means of passageways,flow restrictors (e.g. orifices), valves and vents (not shown), anddirected by vacuum passageways (not shown) to the retentate compartment.These embodiments are particularly suitable for applications where thefraction of interest is the retentate.

To aid and simplify the operation of VacuCon devices 600 and 800 foreither 2-volume or 3-volume operation, valves and vents may be placedbetween the feed compartment 802 and the feed port 801, between thepermeate compartment 814 and the permeate port 812, between theretentate compartment (not shown) and the retentate port 803, betweenthe separation element and the permeate compartment, etc. These valvesand vents may be actuated (a) manually by a human operator, (b) by aseparate apparatus containing sensors that detect the fluid levelsand/or measure the flow rates of the different fractions andelectromechanical actuators, or (c) passively by the state of the liquidfractions within SPF module 806. Examples of passively actuated valvesand vents are: float valves, e.g. between the feed port 801 and the feedcompartment 802 that shut off when the feed sample in feed compartment802 is fully consumed; check valves that allow flow in one directiononly, e.g. at the retentate port, essentially shutting off the retentateport while enabling the withdrawal of the retentate fraction within theflow channel at the end of the permeation by means of a syringe attachedto the retentate port; septa, self-closing or not, located at the any ofthe ports enabling connection by the insertion of a needle (to preservesterility or simply as a shut-off valve actuated by a syringe);hydrophobic vents, e.g. at the end of the flow channel in the SPFseparation element 810 that passively vents the air within the flowchannel into the permeate compartment 814 enabling the priming of theflow channel at the start of the permeation step (in some embodiments aone-way hydrophobic vent at the end of the flow channel may beparticularly useful, according to which air vents in one direction only,from the interior of the channel to the permeate compartment 814, whichcan be done, for example, by designing the shape of the vent such thatthe downstream side of the vent will be flooded with permeate at alltimes, or alternatively, by attaching a check valve to the hydrophobicvent). These valves and vents may be integrated into SPF module 806 (orSPF device 600), or alternatively, may be added as separate componentsattached to SPF module 806 (or SPF device 600). Furthermore, thesevalves and vents may be used alone or in combination depending on theapplication; as shown on FIG. 19 and exemplifying both possibilities,valves 623 and 624 can be simple ON/OFF valves, whereas valves 624 and633 can be 3-way valves that allow shut-off as well as venting dependingon the position of the valves.

In one embodiment particularly suitable when the fraction of interest isthe retentate, SPF module 806 comprises a float valve attached to feedport 801 (that passively closes when there is no liquid in feedcompartment 802), a one-way hydrophobic vent at the end of the flowchannel of SPF separation element 810 (that passively vents the airwithin the flow channel at the start of permeation), and a septumattached at retentate port 803 (that enables the recovery of theretentate fraction by means of syringe). The operation of SPF devices600 and 800 according to this embodiment is as follows:

-   1. The operator attaches feed compartment 802 and permeate    compartment 814 to SPF module 806 forming device 800.-   2. The operator adds feed sample to feed compartment 802.-   3. The operator connects a vacuum source to vacuum port 833,    passively venting the air in the flow channel(s) of SPF separation    element 810 and initiating permeation.-   4. Permeation proceeds without operator attention until the feed    sample is consumed, at which moment the float valve between the feed    compartment 802 and feed port 801 passively shuts off, thereby    stopping permeation.-   5. When the operator notices that feed sample has been consumed, the    operator disconnects the vacuum source effectively venting the    vacuum in the whole device, including the permeate compartment.-   6. The operator then proceeds to puncture the septum at the    retentate port and withdraw the retentate fraction accumulated    within the flow channel(s) of SPF separation element 810. In doing    so, the operator induces reverse permeation since the feed port is    shut-off by the float valve. This recovery method is particularly    effective in recovering retained components that are highly    concentrated on the surface of the membrane, e.g. very high    molecular weight proteins, cells or cell debris. It is understood,    that the manual operations can be automated as described above.

Now referring to FIG. 24, a device 900 includes an integral vacuumincorporated in a housing 908 which includes a feed compartment 902 anda feed conduit 901 for directing a sample into the feed compartment 902.The housing 908 includes a septum 920 sealing one end of the housing908. The feed conduit 901 has one end disposed adjacent to the septum920 and a second end, passing through a portion of a feed separator 924and a portion of a permeate-feed separator 926, and coupled to the feedcompartment 902 disposed within the housing 908. The device 900 furtherincludes a separation element 910 adjacent and fluidly coupled to thefeed compartment 902. The separation element 910 is adjacent and fluidlycoupled to a retentate compartment 904 which is disposed within thehousing at a second end of the housing 908 distally located from theseptum 920. The device 900 further includes a permeate compartment 914disposed between the feed compartment 902 and the septum 920 and apermeate conduit 912. The permeate conduit 912 fluidly couples theseparation element 910 and the permeate compartment 914 and passesthrough a portion of a permeate separator 922 and a portion of thepermeate-feed separator 926. Embodiments of device 900 are suitable forcollection/fractionation of whole human blood.

All three compartments of the device (feed 902, permeate 914, retentate904) are efficiently packaged within the device, in contrast to theVacuCon 600 described above, where the feed reservoir 602 and retentatereservoir 604 are external to the main body of the device 600. Thedevice 900 incorporates functionality for introduction of the sample andwithdrawal of the separated fractions, without the need of valves.Valves are replaced with septum 920 and separators 922, 924 and 926 forthe creation and retention of the vacuum, the introduction of thesample, the inducement of pressure differentials and if necessary, therelease of the vacuum prior to assay. The location and orientation ofthe compartments 902, 914 and 904 enables access to the permeatefraction, which is the fraction of interest for example in clinicalapplications. In on embodiment, the ratio of the membrane area of theseparation element 910 to the volume of the feed compartment 902 isgreater than about 2 cm⁻¹.

In some embodiments, the device 900 is compatible with existing clinicalanalyzers, such that the device 900 can be fed directly to the clinicalanalyzer. Efficient drainage of the permeate fraction from theseparation element of device 900 maximizes volume of the permeatefraction which is collected. The septum 920 forms a reliable seal tocontain the vacuum, The internal volume of the device and of thedifferent compartments need to be sufficiently large to accommodate thesample and the two fractions, the compartments need to be sized relativeto the others to enable the inducement of adequate pressuredifferentials, while the whole device must be small enough to fit intothe sample carrousels of clinical analyzers.

In one embodiment, the separation element 910 comprises a single passTFF module having a flow channel inlet disposed at a first end of theflow channel, a flow channel outlet disposed at a second opposite endand a wall having a surface comprising a filtration membrane asdescribed above. The permeate separator 922, the feed separator 924 andthe permeate-feed separator 926 provide a physical barrier to isolatethe conduits and compartments. The septum 920, which attaches to end ofthe housing 908 seals to the housing circumference and to the concentricfeed conduit 901.

In one embodiment, the separation element is constructed in the form ofa cylinder with a diameter slightly less than 16 mm (e.g., similar to aconventional blood collection tube), and accommodates the length andnumber of hollow fibers as well as the permeate channel. In anotherembodiment the permeate separator 922, feed separator 924 andpermeate-feed separator 926 are integrated into a single plate thatseparates the permeate and feed compartments is designed with the feedconduit 901 concentrically attached to it. The integrated separatorcomponent can be integrated into one of the pieces that form the housing908. Adhesive bonding or a welding process can be used to seal thecomponents to each other, and against the inside surface of the housing,including bonding with medical grade silicone or using ultrasonicwelding methods. Surfaces that make contact with blood can becoated/pre-treated with suitable anticoagulants (e.g., heparin) prior toassembly, followed by final assembly and sealing the components to theinside of the housing.

In operation, the integrated vacuum is adapted to apply first and secondpressure differentials to the membrane disposed within the housing; tofacilitate the separation procedure. The device is precharged with avacuum which drives the blood collection and the subsequentfractionation. The vacuum present in the feed compartment 902 providesthe driving force for blood collection; the vacuum present in theretentate compartment 904 provides the driving force for inducingtangential flow in the flow channel(s) of the separation element 910;and the vacuum present in the permeate compartment 914 provides thedriving force for inducing permeation through the membranes of theseparation element 910.

In one embodiment, the housing 908 comprises a 16 mm×100 mm cylindricalhousing, for example a vacuum tube. Device 900 is capable of addressingmultiple applications by changing the membrane type, the lengths and IDof the hollow fiber, and the number of hollow fibers required.

Now referring to FIGS. 25A-25C and 26, the processing of a blood sampleblood collection/fractionation device 900 includes following steps:

1. Collecting the sample in the feed compartment;

2. Applying a first pressure differential between the feed compartmentand the retentate compartment, the first pressure differential inducingtangential flow in the flow channel;

3. Filtering the sample through the single pass TFF separation elementby applying a second pressure differential between the feed compartmentand the permeate compartment; and

4. Collecting the permeate by injecting a needle through the septum intothe permeate compartment.

As shown in FIG. 25A, the septum 920, which can be a self sealingseptum, is punctured with a needle 930 which is inserted into feedconduit 901 to collect a blood sample. In one embodiment the needle isconnected to a patient and blood flows into the device 900 by virtue ofthe vacuum present in the feed compartment 902 which provides a firstpressure differential between the feed compartment and a retentatecompartment.

As shown in FIG. 25B, the blood sample is drawn into the feedcompartment by the integrated vacuum. In one embodiment, the vacuumlevel is set at the time of manufacture. In an alternate embodiment, theseptum is punctured and connected to a vacuum source to adjust thedesired vacuum level. In one embodiment the blood sample isanti-coagulated as it enters the device.

As shown in FIG. 25C, the vacuum in the retentate compartment 904 causesthe sample to be filtered through the through the single pass TFFseparation element 910 by applying the first pressure differential andby applying a second pressure differential between the feed compartmentand permeate compartment and continues until the entire sample isfiltered as shown in FIG. 26.

Finally, the device can be vented (if necessary) and the plasma samplewithdrawn as shown in FIG. 26 by inserting a needle 934 through theseptum 920 into the permeate compartment 914. In one embodiment, thesingle pass TFF separation element 910 comprises a membrane having poresizes between about 0.001 and about 0.2 micrometer and the integratedvacuum provides trans-membrane pressures (TMP) of less than about 1 bar,a flow rate of about 0.01 to about 100 ml/minute for the collection ofthe sample into the feed compartment and a flow rate of about 0.01 toabout 10 ml/minute through a flow channel of the filter into theretentate compartment to gently sweep the surface of the membrane, and aflow rate of about 0.005 and 5 ml/minute into the permeate compartment.

In some embodiments it is preferable to maintain the device 900 in avertical orientation once the blood collection is finished to insurethat all of the blood sample is filtered through the separation element910. In some embodiments, hollow fiber membranes are preferred for theseparation element because they have a low hold-up volume and do notrequire spacers to create a flow channel. However, flat sheet membranescan be used in other embodiments.

Now referring to FIG. 27, a device 900′, similar in operation to device900 of FIG. 23, having an integral vacuum suitable forcollection/fractionation of whole human blood includes a housing 908′having one end sealed with a septum 920 and an end sealed with a septum921. In device 900′ both the permeate and the retentate can be withdrawnusing a needle. Device 900′ includes a feed compartment 902′ disposedwithin the housing 908′. The device 900′ further includes a separationelement 910 adjacent and fluidly coupled to the feed compartment 902′.The separation element 910 is adjacent and fluidly coupled to aretentate compartment 904′ which is disposed within the housing at asecond end of the housing 908′ distally located from the septum 920. Thedevice 900′ further includes a permeate compartment 914′ disposedbetween retentate compartment 904′ and the septum 921. A benefit of thisdouble-ended device 900′ is that it is simpler to construct, but mayrequire a change in the practices of the clinical labs which routinelyhandle conventional blood collection tubes.

In some applications, the composition of the separated plasma must notbe altered by the separation process due to retention of some solutes bythe membrane, especially large species, in which case microfiltrationmembranes are used in several embodiments. Furthermore, in suchapplications hemolysis is undesirable, and therefore, is kept at aminimum. In membrane plasmapheresis, hemolysis is primarily caused bythe rupture of erythrocyte cells walls when the erythrocytes are forcedinto the membrane pores. The tendency to rupture is increased by longresidence times of the erythrocytes at membrane pores, large membranepores and large trans-membrane pressures. Also, researchers have shownthat membrane pores smaller than 0.5 micrometers are needed to avoidhemolysis when the trans-membrane pressure is maintained at less than 1bar. Using a combination of small pore MF membranes (0.1-0.2 micrometerpores), trans-membrane pressures of less than 1 bar, and flow rates togently sweep the surface of the membrane in certain embodimentsminimizes hemolysis.

The methods described above for generating plasma can recover asubstantial fraction of the plasma sufficient for the clinical assays(≈0.5 ml). For blood samples of 2-3 ml, 50% plasma recovery delivers, incertain embodiments, 0.6-0.8 ml of cell-free plasma. In one embodiment,processing time of the sample is less than 10 minutes. Devices 900 and900′ may use microporous or ultrafiltration membranes according to theanalytes of interest. Devices 900 and 900′ may also have separationelements composed of hollow fibers or of flat sheet membranes inplate-and-frame, stacked-disc or spiral configurations. In theseapplications for plasma recovery the hold-up volume of the permeate isminimized to allow a high recovery of plasma.

Hollow fiber membranes used in the VacuCon 600, device 800 andintegrated vacuum devices 900 and 900′ can be obtained from severalcommercial entities that make hollow fibers. Polysulfone membranes areobtained from GEHealthcare (Northborough, Mass.). Hollow fibers (MF andUF) made from regenerated cellulose can be obtained from multiplesuppliers of hollow fibers. As supplied these materials may containhumectants and antimicrobials. To standardize the composition of thesemembranes the above additives are by extensive extraction with deionizedwater. Following this extraction, the membranes are soaked in methanolsolutions containing 5% glycerin, followed by methanol evaporation ofthe methanol at 50° C. The resulting glycerin treated membranes aretested for spontaneous wetting by blood plasma solutions and theglycerin content adjusted as necessary to insure spontaneous wetting.

It is to be understood that although the preferred embodiments describedherein relate specifically to separations of interest in bio-molecularapplications, the principles, practice and designs described herein arealso useful in other applications. All literature and similar materialcited in this application, including, patents, patent applications,articles, books, treatises, dissertations and web pages, regardless ofthe format of such literature and similar materials, are expresslyincorporated by reference in their entirety. In the event that one ormore of the incorporated literature and similar materials differs fromor contradicts this application, including defined terms, term usage,described techniques, or the like, this application controls.

The section headings used herein are for organizational purposes onlyand are not to be construed as limiting the subject matter described inany way. While the present invention has been described in conjunctionwith various embodiments and examples, it is not intended that thepresent teachings be limited to such embodiments or examples. On thecontrary, the present invention encompasses various alternatives,modifications, and equivalents, as will be appreciated by those of skillin the art. While the teachings have been particularly shown anddescribed with reference to specific illustrative embodiments, it shouldbe understood that various changes in form and detail may be madewithout departing from the spirit and scope of the teachings. Thedescriptions and diagrams of the methods of the present teachings shouldnot be read as limited to the described order of elements unless statedto that effect.

The claims should not be read as limited to the described order orelements unless stated to that effect. It should be understood thatvarious changes in form and detail may be made without departing fromthe scope of the appended claims. Therefore, all embodiments that comewithin the scope and spirit of the following claims and equivalentsthereto are claimed.

What is claimed is:
 1. A module for filtration of a liquid samplecomprising: a housing having a feed port and a retentate port; a filtercomprising a single pass tangential flow filtration (TFF) separationelement comprising a membrane, the filter disposed within the housingcomprising at least one flow channel having a flow channel inletdisposed at a first end of the flow channel and coupled to the feedport, a flow channel outlet coupled to the retentate port and disposedat a second opposite end of the separation element; the housing includesa permeate port which is fluidly coupled to the separation element; thehousing is adapted to place the separation element in communication witha vacuum source; wherein the at least one flow channel has a length acharacterized by a dimensionless length greater than about 4000; a feedreservoir disposed within the housing and fluidly coupled to the feedport; a permeate reservoir fluidly coupled to the permeate port; and avacuum source in communication with the permeate reservoir to apply afirst vacuum to the separation element.
 2. The module of claim 1wherein, a specific membrane area of the at least one channel is greaterthan about 40 cm⁻¹.
 3. The module of claim 1 further comprising aretentate reservoir fluidly coupled to the retentate port.
 4. The moduleof claim 3 wherein the vacuum source is a vacuum box and the permeatereservoir is disposed within the vacuum box.
 5. The module of claim 4wherein the vacuum box provides a second vacuum source coupled to theretentate reservoir.
 6. The module of claim 2, wherein the permeatereservoir is removeably coupled to the housing and the housing furthercomprises a vacuum port.
 7. An integrated sample collection andfractionation device comprising: a housing; a single pass tangentialflow filtration (TFF) separation element disposed within the housingcomprising at least one flow channel having a flow channel inletdisposed at a first end of the flow channel, a flow channel outletdisposed at a second opposite end; a feed compartment disposed withinthe housing and fluidly coupled to the flow channel inlet; a retentatecompartment disposed within the housing and fluidly coupled to the flowchannel outlet; an integrated vacuum adapted to apply a vacuum to theseparation element disposed within the housing; and a permeatecompartment disposed within the housing and fluidly coupled to theseparation element; wherein the housing comprises a vacuum tube having afirst end, a second end and a septum disposed at the first end forreceiving a needle to collect a sample; the device further comprising afeed conduit coupling the septum and the feed compartment; and whereinthe permeate compartment is disposed at the first end of the vacuum tubeand at least partially surrounds the feed conduit.
 8. The device ofclaim 7, further comprising a permeate conduit coupling the permeatecompartment and the separation element; and wherein the feed compartmentis disposed between the separation element and the permeate compartmentat least partially surrounds the permeate conduit.
 9. The device ofclaim 8 further comprising a permeate-feed separator disposed toseparate the feed compartment and the permeate compartment; and whereinthe permeate conduit and the feed conduit pass therethrough.
 10. Thedevice of claim 7, wherein the septum is a self sealing septum.
 11. Thedevice of claim 7 further comprising: a feed conduit coupled to the feedcompartment at a first end and sealed against the septum at a secondend; and a permeate conduit coupled to the separation element at a firstend and the permeate compartment at a second conduit end.
 12. The deviceof claim 7, wherein the housing further comprises a second septumdisposed at a second end of the housing for receiving a needle torecover retentate.
 13. The device of claim 12 wherein the second end ofthe vacuum tube is completely sealed and the device is adapted todirectly feed a clinical analyzer from the first end.